steering ISUZU TROOPER 1998 Service Repair Manual

SAE Ð Society of Automotive Engineers
Sec Ð Secondary
SFI Ð Sequential-port Fuel Injection
SI Ð System International
SIR Ð Supplemental Inflatable Restraint System
SOHC Ð Single Overhead Camshaft
Sol Ð Solenoid
SPEC Ð Specification
Speedo Ð Speedometer
SRS Ð Supplemental Restraint System
ST Ð Start
Sw Ð Switch
SWB Ð Short Wheel Base
SYN Ð Synchronize
TAC Ð Thermostatic Air Cleaner
Tach Ð Tachometer
TBI Ð Throttle Body Injection
TCC Ð Transmission/Transaxle Converter Clutch
TCM Ð Transmission/Transaxle Control Module
TDC Ð Top Dead Center
Term Ð Terminal
TEMP Ð Temperature
TPS Ð Throttle Position Sensor
TRANS Ð Transmission/Transaxle
TURBO Ð Turbocharger
TV Ð Throttle Valve
TVRS Ð Television & Radio Suppression
TVS Ð Thermal Vacuum Switch
3 A/T Ð Three Speed Automatic Transmission/
Transaxle
2WD Ð Two Wheel Drive
4x2 Ð Two wheel Drive
U-joint Ð Universal Joint
V Ð Volt(s)
VAC Ð Vacuum
VIN Ð Vehicle Identification Number
VRRRE Ð Vehicle Refrigerant Recovery and Recycling
Equipment
V-ref Ð ECM Reference Voltage
VRV Ð Vacuum Reducer Valve
VSS Ð Vehicle Speed Sensor
VSV Ð Vacuum Switching Valve
V-6 Ð Six Cylinder ÒVÓ Engine
V-8 Ð Eight Cylinder ÒVÓ Engine
W Ð Watt(s)
w/ Ð With
w/b Ð Wheel Base
w/o Ð Without
WOT Ð Wide Open ThrottleL Ð Liter
lbáft Ð Foot Pounds
lbáin Ð Inch Pounds
LF Ð Left Front
LH Ð Left Hand
LR Ð Left Rear
LS Ð Left Side
LWB Ð Long Wheel Base
L-4 Ð In-line Four Cylinder Engine
MAF Ð Mass Air Flow
MAN Ð Manual
MAP Ð Manifold Absolute Pressure
MAT Ð Manifold Air Temperature
MEM-CAL Ð Memory and Calibration Unit
Max Ð Maximum
M/C Ð Mixture Control
Min Ð Minimum
mm Ð Millimeter
MPFI Ð Multi-Port Fuel Injection
MPG Ð Miles per Gallon
MPH Ð Miles per Hour
M/T Ð Manual Transmission/Transaxle
MV Ð Millivolt
NA Ð Natural Aspirated
NC Ð Normally Closed
Nám Ð Newton Meters
NO Ð Normally Open
NOx Ð Nitrogen, Oxides of
OD Ð Outside Diameter
O/D Ð Over Drive
OHC Ð Overhead Camshaft
OL Ð Open Loop
O
2Ð Oxygen
PAIR Ð Pulse Air Injection Reactor System
P/B Ð Power Brakes
PCV Ð Positive Crankcase Ventilation
PFI Ð Port Fuel Injection
PRESS Ð Pressure
PROM Ð Programmable Read Only Memory
P/N Ð Park/Neutral
P/S Ð Power Steering
PSI Ð Pounds per Square Inch
Pt. Ð Pint
Pri Ð Primary
PWM Ð Pulse Width Modulated
Qt Ð Quart
REF Ð Reference
RF Ð Right Front
RFI Ð Radio Frequency Interference
RH Ð Right Hand
RPM Ð Revolutions per Minute
RPO Ð Regular Production Option
RR Ð Right Rear
RS Ð Right Side
RTV Ð Room Temperature Vulcanizing
RVB Ð Rear Vacuum Brake
RVR Ð Response Vacuum Reducer
RWAL Ð Rear Wheel Antilock Brake
RWD - Rear Wheel Drive
GENERAL INFORMATION 0AÐ13

0BÐ2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
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1215
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1820
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2425
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3030
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3635
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4240
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4845
27
5450
30
6055
33
6660
36
7265
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7870
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8475
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9080
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9685
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10290
54
10895
57
114100
60
120
GASOLINE ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
* Timing belt
Spark plugs (For leaded fuel use)
Spark plugs (For unleaded fuel use)
Exhaust system
Radiator coolant concentration
Cooling system for water leakage
All hoses and pipes in engine compartment
for clog or damage
Fuel filter
Fuel leakage
Fuel tank
* Air cleaner element
Pre air cleaner
Engine drive belt
Valve clearance
O
2 Sensor (For leaded fuel use)
O
2 Sensor (For unleaded fuel use)-
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(Replace every 165,000 km or 100,000 miles)
(Replace every 165,000 km or 100,000 miles)
(Check and adjust if necessary every 100,000 km or 60,000 miles)
(Replace every 150,000 km or 90,000 miles)
CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid leakage
*
(1)Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
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Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)
FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
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ATATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
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(1): Adjust or change automatic transmission fluid.
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”.

0BÐ4 MAINTENANCE AND LUBRICATION
DIESEL ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
3
610
6
1215
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1820
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2425
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3030
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3635
21
4240
24
4845
27
5450
30
6055
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6660
36
7265
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7870
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8475
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9080
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9685
51
10290
54
10895
57
114100
60
120
DIESEL ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
Idling speed and acceleration
Fan belt tension and damage
Timing belt
Exhaust system
All hoses and pipes in engine compartment
for clog or damage
Valve clearance
* Air cleaner element
Fuel filter
Radiator coolant concentration
Cooling system for water leakage-
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NOTE: In the 4JXI-TC diesel engine, there is provided sub (2nd) oil filter for fuel injection at the upper part of crank case on the left
side of the engine. This oil filter maintenance-free and does not need a periodic replacement. See reverse side the (back)
cover for installation location of the sub (2nd) oil filter.(Replace every 200,000 km or 125,000 miles)
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”. CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
* Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
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ATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
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0BÐ6 MAINTENANCE AND LUBRICATION
Item IntervalCondition
ABCD A+D
Engine oil G : Change every 5,000 km (3,000 miles)
D : Change every 5,000 km (3,000 miles) ll
Engine oil filter G : Replace every 10,000 km (6,000 miles)
D : Replace every 5,000 km (3,000 miles) ll
Air cleaner element G : Replace every 20,000 km (12,000 miles)
D : Replace every 40,000 km (25,000 miles)l
Power steering fluid Replace every 50,000 km (30,000 miles)ll
Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)l
Universal joints and sleeves Inspect for wear and lubricate every 7,500 km (4,500 miles)ll
Transmission with MT Change every 20,000 km (12,000 miles)
transfer case oil after changing at initial 10,000 km (6,000 miles)l
Transmission :
AT
Change every 32,000 km (20,000 miles) lll l
Transfer:
TF Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)l
Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 5,000 km (3,000 miles) l
Disc brake pads and discs Inspect every 5,000 km (3,000 miles)lll
Timing belt G : Replace every 120,000 km (75,000 miles)ll
EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE
Explanations of the services listed in the proceeding
Maintenance Scheduled are presented in ÒService
InformationÓ section of each manual.Replace all questionable parts and note any
necessary repairs as you perform these
maintenance procedures.
MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS
Severe driving conditions
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads

0BÐ8 MAINTENANCE AND LUBRICATION
FLUID TYPE
Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade
LUBRICATION MAKE BRAND / TYPEGRADE
API ACEA
ISUZU GENUINE BESCO ATF II, ATF III
EXXON / ESSO ESSO ATF D (DEXRONÒ
II-D)
Automatic transmission MOBIL MOBIL ATF (DEXRONÒ
III)
Power steering CALTEX ATF HD (DEXRONÒ
II)
SHELL SHELL DONAX TA (DEXRONÒ
II-D)
ELF ELFMATIC G3 (DEXRONÒ
III)
TOTAL TOTAL FLUID IID (DEXRONÒ
II-D)
ISUZU GENUINE
BESCO L-2 GREASE (No.2), L-3 GREASE (No.3)Propeller shaft sliding EXXON / ESSO RONEX MP (No.2)
yoke, Universal joint MOBIL MOBILGREASE HP 222 (No.2)
Grease fittingCALTEX / TEXACOSTARPLEX-2 (No.2)
(General purpose grease)SHELL SHELL RETINAX A (No.2)
TOTAL MULTIS EP2, EP3 (No.2, No.3)
Propeller shaft slidingISUZU GENUINE ONE LUBER MO GREASE
yoke EXXON / ESSO BEACON Q2 (No.2)
Universal joint EXXON / ESSO MULTIPURPOSE GREASE (Moly) (No.2)
General purpose greaseCALTEX MOLYTEX GREASE EP2 (No.2)(in Molybdenum)TOTAL TOTAL MULTIS MS2 (No.2)
ISUZU GENUINE BESCO LLC SUPER TYPE E
TEXACO / CALTEX HAVOLINE EXTENDED LIFE ANTIFREEZE
Engine cooling system COOLANT
HAVOLINE XLC
EXTENDED LIFE COOLANT 6280
NOTE:
When the recommended lubricants are specified in the workshop manual, follow them.

1B Ð 24 AIR CONDITIONING
3
4
2
7 86 1
5
4. Remove serpentine belt.
·Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
5. Disconnect refrigerant line connector.
·When removing the line connector, the connecting
part should immediately be plugged or capped to
prevent foreign matter from being mixed into the
line
6. Remove compressor.
Installation
1) Install compressor.
·Tighten the compressor fixing bolts to the specified
torque.
Compressor Fixing Torque Nám (kgám / lbáft)
19 (1.9 / 14)
2) Connect refrigerant line connector.
·Tighten the refrigerant line connector fixing bolts
to the specified torque
Refrigerant Line Bolt Torque Nám (kgám / lbáft)
15 (1.5 / 11)
·O-rings cannot be reused. Always replace with new
ones.
·Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
3) Install serpentine belt.
·Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
850RY00001
Legend
(1) Tensioner
(2) Idle Pulley
(3) Cooling Fun Pulley
(4) Serpentine Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator

1B Ð 26 AIR CONDITIONING
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
·Refer to Refrigerant Recovery in this section.
3. Disconnect magnetic clutch harness connector.
4. Remove radiator fan shroud.
5. Remove radiator fan.
·When the fan is removed, be sure to tighten
the fan fixing nuts temporarily to their original
positions.
6. Remove serpentine belt.
·Move serpentine belt tensioner to loose side
using wrench, then remove serpentine belt.
Legend
(1) Tensioner
(2) Idle Pulley
(3) Cooling Fan Pulley
(4) Serpentine Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator
7. Disconnect refrigerant line connector.
·When removing the line connector, the
connecting part should immediately be
plugged or capped to prevent foreign matter
from being mixed into the line.
8. Remove compressor.
Installation
1. Install compressor.
·Tighten the compressor fixing bolts to the
specified torque.
Compressor Fixing Torque Nám (kgám / lbáft)
19 (1.9 / 14)
2. Connect refrigerant line connector.
·Tighten the refrigerant line connector fixing
bolts to the specified torque.
Refrigerant Line Bolt Torque Nám (kgám / lbáft)
15 (1.5 / 11)
·O-rings cannot be reused. Always replace with
new ones.
·Be sure to apply new compressor oil to the O-
rings when connecting refrigerant lines.
3. Install serpentine belt.
·Move serpentine belt tensioner to loose side
using wrench, then install serpentine belt to
normal position.
4. Install radiator fan.
5. Install radiator fan shroud.
6. Connect magnetic clutch harness connector.
3
4
2
7 86 1
5
850RX003

1B Ð 28 AIR CONDITIONING
REMOVAL
Preparation:
·Battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section)
1. Air Duct (Turbo to air cleaner)
Cover up the air duct connecting portion to prevent
foreign materials from getting into the turbo and the
air cleaner.
2. Magnetic Clutch Harness Connector
3. Drive Belt
Loosen the power steering pump unit fixing bolts,
then loosen the drive belt adjustment bolt and
remove the drive belt.
4. Refrigerant Line Connector
5. Compressor
Drive belt
Power steering
pump Tension
adjustment bolt
INSTALLATION
5. Compressor
Tighten the compressor fixing bolts to the specified
torque.
Compressor Bolt Torque Nám (kgám / lbáft)
40 (4.1 / 30)
4. Refrigerant Line Connector
·O-rings cannot be reused. Always replace with new
ones.
·Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
·Tighten the refrigerant line connector to the
specified torque.
Refrigerant Line Bolt Torque Nám (kgám / lbáft)
27 (2.8 / 20)

AIR CONDITIONING 1B Ð 29
3. Drive Belt
1) Temporary tighten the power steering pump unit
fixing bolts.
2) Push the drive belt when the force of 98N {10kgf}.,
and adjust the drive belt tension by tightening
drive belt tension adjustment bolt, till the 14 ~17
mm (0.55 ~0.67 in) of deflection of the belt is
obtained. Then tighten the power steering pump
fixing bolts.
2. Magnetic Clutch Harness Connector
1. Air Duct (Turbo to air cleaner)
Power steering
pump pulley
Tension adjustment
bolt
Crank pulley Drive beltCompressor98N{10kgf}
14™17mm
(0.55™
0.67 in.)
850RY00002

AIR CONDITIONING 1B Ð 31
REMOVAL
Preparation:
·Battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section)
1. Air Duct (Turbo to air cleaner)
Cover up the air duct connecting portion to prevent
foreign materials from getting into the turbo and the
air cleaner.
2. Magnetic Clutch Harness Connector
3. Drive Belt
Loosen the power steering pump unit fixing bolts,
then loosen the drive belt adjustment bolt and
remove the drive belt.
4. Refrigerant Line Connector
5. Compressor
CompressorTension adjustment bolt
Tension pally
14~17mm
(0.55-0.67in)
98N{10kgf}
Crank shaft pully
INSTALLATION
5. Compressor
Tighten the compressor fixing bolts to the specified
torque.
Compressor Bolt Torque Nám (kgám / lbáft)
40 (4.1 / 30)
4. Refrigerant Line Connector
·O-rings cannot be reused. Always replace with new
ones.
·Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
·Tighten the refrigerant line connector to the
specified torque.
Refrigerant Line Bolt Torque Nám (kgám / lbáft)
27 (2.8 / 20)
850RY00003