service ISUZU TROOPER 1998 Service Repair Manual

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
00 SERVICE INFORMATION
1A HEATING AND VENTILATION
1B AIR CONDITIONING
1D COMPRESSOR OVERHAUL

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
00 SERVICE INFORMATION
2A FRONT END ALIGNMENT

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4JG2
4JX1 SECTION No. CONTRNTS
00 SERVICE INFORMATION
6A ENGINE MECHANICAL
6A2 4JG2-NA / 4JG2-TURBO ENGINE
6B ENGINE COOLING
6C FUEL SYSTEM
6D ENGINE ELECTRICAL
6E -
6F EXHAUST
6G -
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL
6J INDUCTION

GENERAL INFORMATION 0AÐ1
SECTION 0A
GENERAL INFORMATION
CONTENTS
PAGE
General Repair Instructions...............................................0AÐ 2
How To Use This Manual.................................................0AÐ 3
Identification...........................................................0AÐ 6
Lifting Instructions......................................................0AÐ 8
Torque Specifications....................................................0AÐ10
Recommended Liquid Gasket.............................................0AÐ11
Recommended Thread Locking Agents.....................................0AÐ11
Abbreviations Charts....................................................0AÐ12
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners
or fasteners joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.

GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the
front or rear wheels before lifting the vehicle.
2. Use covers on the vehicle body, seats, and
floor to prevent damage and/or
contaminations.
3. Disconnect the grounding cable from the
battery before performing service operations.
This will prevent cable damage or burning due
to shortcircuiting.
4. Raise the vehicle with a jack set against the
recommended lifting points (see ÒLifting
instructionsÓ in this section).
5. Support the vehicle on chassis stands.
6. Handle brake fluid and antifreeze solution with
great care.
Spilling these liquids on painted surfaces will
damage the paint.
7. The use of the proper tool(s) and special tool(s)
where specified is essential to efficient,
reliable, and safe service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gasket, plastic clips,
O-rings, oil seals, lock washers, and self-
locking nuts at disassembly.
Normal function of these parts cannot be
guaranteed if they are reused.
10. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct
reassembly.11. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and
design according to installation positions.
12. Clean all parts before inspection or
reassembly.
13. Clean the oil ports and other openings with
compressed air to make certain that they are
free of dirt and obstructions.
14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before
installation.
15. Use the recommended liquid gasket to prevent
leakage.
16. Carefully observe all nut and bolt torque
specifications.
17. When service operation is completed, make a
final check to be sure service has been done
properly and problem has been corrected.
18. When removing or replacing parts that require
refrigerant to be discharged from the air
conditioning system, be sure to use the
following tools to recover and recycle the
Refrigerant-134a (R-134a).
For 134a:
Use the R-134a Refrigerant Recovery/Recovery/
Recycling/Recharging/System (ACR
4) or its
equivalent to prevent the discharge of
refrigerant into the air.
0AÐ2 GENERAL INFORMATION

GENERAL INFORMATION 0AÐ3
HOW TO USE THIS MANUAL
1. Find the applicable section by referring to the
table of contents on the introduction page of
each manual.
2. In ÒService InformationÓ, an opening section of
each manual, the troubleshooting, maintenance
servicing, service data and/or information on
special tools required for the service operations
described in the next subsequent sections are
arranged and compiled so concisely that you
can see at a first glance.
3. Each section except the Service Information
section is basically arranged in the following
order of headings:
General description
On-vehicle service
Unit repair4. The service operations are in two groups: one is
the ÒOn-vehicle serviceÓ where operations can
be directly performed on the vehicle, and the
other is the ÒUnit repairÓ where the operations
are done on the work bench after removing the
unit from the vehicle.
5. Each service operation section begins with a
disassembled view of unit or equipment, which
is useful to find relative components, service
procedure, availability and contents of repair
kits, etc.
The number represents sequence of
removal or disassembly
Removal of unnumbered the parts
(excluding bolts, nuts, washers,
gaskets, cotter pins, etc.) is
unnecessary unless replacement is
needed.
Where parts replacement requires
specific information, instructions are
given in ÒInspection and RepairÓ.
This frame is to be removed as a
large disassembly with all the parts
assembled in the frame. Each one of
the parts in the frame is removed as
a small disassembly.
Parts to be removed or installed as a
unit.
H Parts contained in repair kit.
H Indicates repair kit availability.
When the installation (reassembly)
procedure is the reverse order of the
removal (disassembly) procedure,
the sequence of service operation
and the parts names will be omitted.
Name of parts listed in sequence of
service operation.

For illustrations where there are few items to
be performed:
The sequence of removal
(disassembly) and the parts names
will be given.
The symbol mark attached to the title
indicates the action to be taken in the
operations of each title.
Example for this case;
1st step Ð Reassemble pinion shaft
The numbers given to the installation
(assembly) procedure are the same
as those given in the removal
(disassembly) procedure in the
illustration. Therefore, start with the
larger number during reassembly.
The titles of operations done in the
illustration are given in bold letters.
They are described in the order of
the procedure of the operations.
Special tools are identified with tool
name and/or tool number.
The drawing illustrates how the tool
is used.
Service data and specifications are
listed in table.
Important note.
The action symbol indicates the step
of service to be followed.
Refer to the following paragraph for
the meaning of each symbol.
information such as the notes in each operation,
and places where special tools are to be used
and their usage, and the specified service data.
0AÐ4 GENERAL INFORMATION
6. After the illustration, the details of each
operation are shown in the order the operations
are carried out in the illustration. Refer to the
explanations when checking important

GENERAL INFORMATION 0AÐ5
7. In this manual, the following action symbols
are used to indicate the type of service
operations to be performed.
. . . Remove or disconnect . . . Adjust
. . . Install or connect . . . Clean
. . . Disassemble . . . Pay close attention - Important
. . . Reassemble . . . Tighten to specified torque
. . . Align the marks . . . Use special tool(s)
. . . Correct direction . . . Lubricate with oil
. . . Inspect . . . Lubricate with grease
. . . Take measurement . . . Use liquid gasket
8. The service standard is indicated in terms of
ÒStandardÓ and ÒLimitÓ.
The ÒStandardÓ means the assembly standard
and standard range within which the parts areconsidered serviceable.
ÒLimitÓ indicates the limit value (Correction or
replacement is necessary when measurement
is beyond this limit.)

GENERAL INFORMATION 0AÐ7
TRANSMISSION SERIAL NUMBER
Manual: Stamped on the left side of the transmission
intermediate plate.
Automatic: Stamped on the identification plate, located on
the left side of the transmission above the
mode switch.
96
0000 000018PART No.
SERIAL No. SALHYDRAMATIC
STRASBOURGMADE IN FRANCEG 20272
FP
SERVICE PARTS IDENTIFICATION PLATE
The Vehicle Information Plate (Service Parts ID plate) is
provided on all vehicle models.
It is located on the center dash wall inside the engine
compartment. The plate lists the VIN (Vehicle Identification
Number), paint information and all production options and
special equipment on the vehicle when it was shipped
from the factory.
Service parts ID plateISUZU MOTORS L T D. JAPAN
V.I.N.
M.D.
ENGINE
GRADETRANS.
TIRE
BODY TYPE
B. COLOR/TRIM
OPTION
905RW015
905RW018
905RW007

MAINTENANCE AND LUBRICATION 0BÐ1
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
PAGE
Maintenance Schedule...................................................0BÐ 2
Recommended Fluids, Lubricants and Fuels.................................0BÐ 7
Oil Viscosity Chart.......................................................0BÐ10
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners
or fasteners joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.