window ISUZU TROOPER 1998 Service Repair Manual

1A Ð 4 HEATING AND VENTILATION
AIR SELECT KNOB
The air selector knob allows you to direct heated air
into the passenger compartment through different
outlets.
1.Vent- In this position, air is discharged from
the upper air outlet. Air quantity is controlled
by the fan control knob.
2.Bi-Level- In this position, air flow is divided
between the upper air outlets and the foot air
outlets, with warmer air delivered to the floor
outlets than the air delivered to the upper air
outlets.
3.Foot- In this position, air flow is delivered to
the foot while sending approx. 30% of total
amount of air to the windshield
4.Def/Foot- In this position, air flow is delivered
to the foot, while sending approx. 40% of total
amount of air to the windshield.
5.Defrost- In this position, most of the air is
delivered to the windshield and a small
amount is delivered to the side windows.
Moving the air source select lever to the ÒCIRCÓ
position provides quickest heat delivery by closing
the blower assembly mode door. In this position,
outside air is not delivered to the passenger
compartment.
AIR SOURCE SELECT LEVER
The intake of outside air and the circulation of inside
air are controlled by sliding this lever left or right.
FAN CONTROL KNOB
This knob controls the blower motor speed to
regulate the amount of air delivered to the defrost,
foot, and ventilation ducts:
1. Low
2. Medium Low
3. Medium High
4. High
TEMPERATURE CONTROL KNOB
When the temperature control knob is in the
ÒCOLDÓ position, the air mix door closes to block
the flow of air to the heater core.
When the temperature control knob is in the
ÒHOTÓ position, the air mix door opens to allow air
to pass through the heater core and heat the
passenger compartment.
Placing the knob in an intermediate position will
cause a lesser or greater amount of air to reach the
heater core. In this mode the passenger compart-
ment temperature can be regulated.
Heater core Heater unit
TO VENT OUTLETAir mix door
VENT MODETO FOOT TO VENT OUTLET
BI-LEVEL MODE
FOOT MODE TO FOOT OUTLET
TO DEF OUTLET(LHD)
DEF/FOOT MODE TO FOOT OUTLETTO DEF OUTLETDEF MODE TO DEF OUTLET
: COLD AIR
: HOT AIR
: TEMP.CONTROLLED AIR

1B Ð 22 AIR CONDITIONING
Almost transparent.
A flow of bubbles
can be seen, but
they disappear
when the throttle is
opened.
The sight glass provides accurate diagnosis only under the following conditions.
If the vehicle can be tested under these conditions, check the sight glass appearance and compare to the
chart.
* Engine speed Idling
* A/C switch ÒONÓ
* Blower fan operating at highest speed
* Air source selector lever at ÒRECIRCÓ
* Temperature control knob at coldest position
* Ambient temperature below 30¡C (86¡F) and humidity below 70% (See NOTE 1)
* High side pressure less than 1863 kPa (19 kgácm
2/ 270 PSI) (See NOTE 2)
NOTE 1
If the vehicle cannot be moved to a testing location that meets these specifications, then the sight glass
cannot be used for diagnosis. You must discharge and recover the refrigerant, then recharge the system
with the specified amount of refrigerant. Then continue checking the system performance.
NOTE 2
If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must
discharge and recover the refrigerant, then recharge the system with the specified amount of refrigerant.
Then continue checking system performance.
Reading Sight Glass
High and low
pressure pipe
temperature
Sight glass
condition
Air condi-
tioner cycle
condition
The high pressure
pipe is hot and the
low pressure pipe is
cold. There is a dis-
tinct difference in
temperature bet-
ween them.
OK
The high pressure
pipe is warm and
the low pressure
pipe is cool. There
is no great dif-
ference in tempera-
ture between them.
A flow of bubbles
always can be seen.
It appears some-
times transparent,
and sometimes
frothy.
NG
(Not enough
refrigerant)
There is little dif-
ference in tempera-
ture between the
high pressure pipe
and the low press-
ure pipe.
Something like fog
faintly can be seen.
NG
(Almost no
refrigerant)
The high pressure
pipe is hot and the
low pressure pipe is
slightly warm.
There is a difference
in temperature bet-
ween them.
Even at idle with the
fan at ÒHIÓ (with the
window fully open),
the bubbles cannot
be seen.
NG
(Too much
refrigerant)

4C±26
DRIVE SHAFT SYSTEM
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 N´m (11.8 kg´m/85 lb ft)
5. Apply 150g of the specified grease in BJ .
6. Install dust seal .
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction. After
installation, check that the bellows is free from
distortion.
412RS017
9. Install another bellows and fix band.
10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS013
13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS018
14. Install spacer.
15. Install snap ring.
16. Enclose 150g of the specified grease in DOJ case,
then install drive shaft joint assembly. After
reassembly, move the DOJ longitudinally several
times to get to fit.
17. Install the circlip (1) so that open ends are positioned
away from the ball groove.

4JG2-NA/4JG2-TURBO ENGINE 6A 2Ð 27
REMOVAL
Preparation
·Remove battery. (two batteries for cold area)
·Disconnect window washer hose, and remove
engine hood.
·Drain coolant.
·Space stand and front right tire.
1. Radiator Hose : Upper
·Disconnect upper radiator hose from engine side.
2. Air Cleaner Cover & Air Duct
3. Intercooler Assembly (4JG2-T Only)
·(Refer to intercooler removal steps in this section)
4. Oil Level Gauge Guide Tube
5. P/S Pump
·Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belts.
·Remove two fixing bolts (front side). A fixing nut
(rear side) and support P/S pump asm with oil
hoses by tying to body side.
6. A/C Compressor Assembly
·Remove A/C compressor fixing bolt (rear under
side of compressor) by using a long extension bar
at under side of wheel arch.
·Disconnect magnetic clutch harness connector.
·Remove fixing bolts (upper and front lower side of
compressor) and set A/C compressor asm with
pipe line on battery carrier.
7. Water Hose; CSD
·Disconnect CSD water hoses from heater hose
side.
8. Engine Harness
·Disconnect five harness connectors from units on
thermostat housing.
9. Heater Hose: Rear Side
·Disconnect heater hose from heater pipe.
10. Water Bypass Hose
·Disconnect water bypass hose from water pump.
11. Water Inlet Hose: Turbo (4JG2-T Only)
·Disconnect from water outlet pipe of engine.
12 Water Outlet Hose: Turbo (4JG2-T Only)
·Disconnect from water inlet pipe of engine.
13 Oil Feed Pipe: Turbo (4JG2-T Only)
·Remove two joint bolts (from turbocharger and
cylinder block) and oil feed pipe.
14. Oil Return Pipe Fixing Nut (4JG2-T Only)
·Remove oil return pipe fixing nut from cylinder
block.
15. Oil Cooler Hose

6A2 Ð 48 4JG2-NA/4JG2-TURBO ENGINE
ENGINE ASSEMBLY
REMOVAL
Preparation
·Space stands and removal front tires.
·Removal battery. (two batteries for cold area)
·Drain coolant.
·Disconnect window washer hose and remove engine
hood.
1. Radiator Hose
·Disconnect upper and lower hoses from engine
side.
2. Fan Shroud
·Disengage clips and remove upper and lower fan
shrouds.

6A2 Ð 52 4JG2-NA/4JG2-TURBO ENGINE
6. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler installation steps in this
section.
5. Air Cleaner Cover & Duct
4. Radiator Assembly
·Install cushion rubber in under left and right part
of radiator and position radiator.
·Fix radiator by bracket.
3. Cooling Fan Assembly
·Install cooling fan asm and tighten fixing bolts to
the specified torque.
2. Fan Shroud
1. Radiator Hose
·Connect upper and lower hose to engine side.
·Pour coolant in to radiator.
·Install battery.
·Connect window washer hose.
10. A.C. Generator Harness
9. Engine Ground Cable
·Attached ground cable to A/C compressor bracket.
8. P/S Pump Assembly
·Install P/S pump asm in engine and tighten
temporarily fixing nut.
7. P/S Pump Drive Belt
·Install drive belts adjust belt tension by adjusting
bolt and tighten locking bolt to the specified
torque.
·Refer to ÒDrive Belt AdjustmentÓ in section 6B.
8 (0.8/69)N·m(Kg·m/lb·in)
40 (4.1/30)N·m(Kg·m/lb·ft)

6A – 28 ENGINE MECHANICAL
ENGINE ASSEMBLY
For General Export
For Europe
F06R200004
REMOVAL
1. Remove battery.
2. Drain engine coolant
3. Disconnect window washer hose and remove
engine hood.
4. Radiator Hose
1) Disconnect upper and lower hoses from engine
side.
5. Fan Shroud
1) Disengage clips and remove upper and lower
fan shrouds.
6. Cooling Fan Assembly
1) Remove cooling fan assembly fixing nuts,
cooling fan assembly.
7. Radiator Assembly1) Remove bracket and radiator assembly.
8. Air Cleaner Cover & Air Duct
9. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
10. Engine Ground Cable
1) Disconnect ground cable from A/C compressor
bracket.
11. AC Generator Harness
1) Disconnect B terminal and harness connector
from AC generator.
12. A/C Compressor Assembly
1) Disconnect magnetic clutch harness connector.
2) Remove A/C compressor fixing bolt (rear under
side of compressor).
3) Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor
assembly with pipe lines on battery carrier.

ENGINE MECHANICAL 6A – 29
13 Vacuum Hose
1) Disconnect vacuum hose from vacuum pump.
14. Starter Harness
1) Disconnect B terminal and put cable harness
close to chassis side.
2) Disconnect S terminal connector.
15. Engine Harness
1) Disconnect engine harness close to engine side.
16. Fuel Pipe
1) Remove fuel pipe from fuel pump and take care
not to spill fuel and let dust enter.
17. Engine Ground Cable
1) Disconnect ground cable from left rear side of
timing gear case.
18. Vacuum Hose: Vacuum Tank
Disconnect vacuum hose from vacuum pump side.
19. Glow Plug Harness
20. Transmission Assembly
1) Set transmission support tool under the
transmission.
2) Remove transmission rear mount.
3) Remove transmission fixing bolt from rear of
engine assembly except two bolts.
4) Carefully hang up engine assembly with a hoist.
5) Remove remaining two transmission fixing bolts.
6) Remove transmission assembly.
7) Remove heater hose.
8) Disconnect wire harness connector for shift on
the fly.
9) Remove vacuum hose.
21. Prepare Engine Stand
22. Engine Assembly
1) Remove engine mount fixing bolts.
2) Carefully hang up the engine assembly.
3) Take out the engine assembly making sure not
to damage the brake oil pipe and other pipe etc.
INSTALLATION
1. Engine assembly
1) Install engine in mounting position by using
hoist.
2. Transmission Assembly
1) Refer to transmission installation steps in
section 7.
3. Engine Mounting
1) After all fixing bolts (left: two bolts, rights: two
bolts) were inserted in every hole, tighten fixing
bolts to the specified torque.
Torque: 40 N·m (4 kg·m/29 lb·ft)
4. Glow Plug Harness
5. Vacuum Hose
1) Connect Vacuum Hose to Vacuum Pump
6. Engine Ground Cable
7. Fuel Pipe
1) Install fuel pipe to fuel pump.
8. Engine Harness
9. Starter Harness
10. A/C Compressor Assembly
1) Tighten temporarily the fixing bolts (upper and
front lower sides of compressor.)2) Tighten fixing bolt (rear under side of
compressor) to the specified torque.
3) Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.
Torque: 40 N·m (4 kg·m/29 lb·ft)
Legend
(1) Tensioner
(2) Bolt
(3) Bracket
(4) A/C compressor
(5) Bolt
11. A.C Generator Harness
12. Engine Ground Cable
1) Tighten ground cable to A/C compressor
bracket.
13. Air Cleaner cover & Duct
14. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
15. Radiator Assembly
1) Install rubber cushion in under left and right part
of radiator and position radiator.
2) Fix radiator with bracket.
16. Cooling Fan Assembly
1) Install cooling fan assembly and tighten fixing
bolts to the specified torque.
Torque: 8 N·m (0.8 kg·m/5.8 lb ft)
17. Fan Shroud
18. Radiator Hose
1) Connect upper and lower hose to engine side.
2) Pour coolant into radiator.
19. Install battery.
20. Connect window washer hose and install engine
hood.
1
2
3
4
5
'PS
&VSPQF
F06R200005

7A±28
AUTOMATIC TRANSMISSION (4L30±E)
Removal
1. Disconnect battery ground cable.
2. Remove transfer control lever knob.
3. Remove front console.

Disconnect wiring harness connectors from front
console.
4. Disconnect shift lock cable (1) from the selector lever
assembly side.
256RW012
5. Disconnect shift control rod (2) from the selector lever
assembly side.
256RW013
6. Disconnect wiring harness connectors from the
selector lever assembly.
7. Remove selector lever assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
Adjustment of select lever and control rod
1. Place the vehicle on a level surface.NOTE: If the vehicle is not on level surface, the shift
select cable set positions will vary with the movement of
engine. To prevent possible misadjustment of the cable,
the vehicle must be placed on a level surface.
2. Install the shift control rod (1) to the transmission
select lever (2), and then place the lever in the ªNº
position.
3. Set select lever in the ªNº position.
4. Push select lever forward (ªRº position side) and
secure it (using a rubber band (3), etc.) so that the pin
comes into contact with the wall of the detent plate.
5. Install the shift control rod (1) to the selector lever arm
(4).
Torque: 32 Nwm (3.3 kg´m/24 lb ft)
NOTE: Do not apply oil to the threaded portions.
256RW014
6. After adjustment, make sure that the selector lever
operates normally, and that each selector position is
properly indicated. (The red mark shows through the
window.)
Adjustment of shift lock cable
1. Set ignition key in ªLOCKº position and selector lever
in ªPº position.
2. Adjust cable screw cap on selector lever side to
provide a gap (slack for cable) of 1 ± 2 mm between
rod on steering lock side and stopper.
Adjust cap as follows:
a. Pull screw cap (1) in arrow direction to remove
inner cable slack.
b. With cable kept as (a), adjust gap between nut (2)
and bracket to 5 mm (0.2 in).
c. Lock inner cable by turning nut (3) while holding nut
(2) in place.
Torque : 3.7 Nwm (38 kg´cm/33 lb in)
NOTE: Clean the cable threads, and do not apply oil to
them.

WIRING SYSTEM 8DÐ1
BODY AND ACCESSORIES
WIRING SYSTEM
CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . 8DÐ3
General Description . . . . . . . . . . . . . . . . . . . 8DÐ4Notes for Working on Electrical Items . . 8DÐ4
Symbols and Abbreviations . . . . . . . . . . . 8DÐ10
Parts for Electrical Circuit . . . . . . . . . . . . . 8DÐ12
Reading the Circuit Diagram . . . . . . . . . . 8DÐ21
Main Data and Specifications . . . . . . . . . . . 8DÐ24 Fuse, Fusible Link and Circuit Breaker Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ24
Relay Location . . . . . . . . . . . . . . . . . . . . . . 8DÐ27
Diode Location . . . . . . . . . . . . . . . . . . . . . . 8DÐ30
Grounding Point . . . . . . . . . . . . . . . . . . . . . 8DÐ33
Cable Harness Routing . . . . . . . . . . . . . . . 8DÐ45
Fuse Block Circuit . . . . . . . . . . . . . . . . . . . . . 8DÐ53 Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ54
Start and Charging . . . . . . . . . . . . . . . . . . . . 8DÐ67 General Description . . . . . . . . . . . . . . . . . . 8DÐ67
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ68
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ70
Powertrain Control Module (PCM) . . . . . . . 8DÐ80 General Description . . . . . . . . . . . . . . . . . . 8DÐ80
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ81
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ93
QOSIII (4JG2) . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ111 General Description . . . . . . . . . . . . . . . . . . 8DÐ111
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ112
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ114
QOS and EGR System (4JG2) . . . . . . . . . . . 8DÐ118 General Description . . . . . . . . . . . . . . . . . . 8DÐ118
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ119
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ122
Headlight and Fog Light . . . . . . . . . . . . . . . . 8DÐ127 General Description . . . . . . . . . . . . . . . . . . 8DÐ127
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ128
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ130
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ134
Rear Foglight . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ150 Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ151
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ152
Headlight Leveling . . . . . . . . . . . . . . . . . . . . 8DÐ153 General Description . . . . . . . . . . . . . . . . . . 8DÐ153
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ154
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ155
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ156
Clearance Light, Taillight and License Plate Light . . . . . . . . . . . . . . . . . . . . 8DÐ159 General Description . . . . . . . . . . . . . . . . . . 8DÐ159
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ160
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ163
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ168
Interior Illumination Light . . . . . . . . . . . . . . 8DÐ180 General Description . . . . . . . . . . . . . . . . . . 8DÐ180
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ181
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ185
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ192
Turn Signal Light and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ193
General Description . . . . . . . . . . . . . . . . . . 8DÐ193
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ194
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ197
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ202
Stoplight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ208 General Description . . . . . . . . . . . . . . . . . . 8DÐ208
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ209
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ212
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ216
Backup Light. . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ220 General Description . . . . . . . . . . . . . . . . . . 8DÐ220
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ221
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ223
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ227
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ230 General Description . . . . . . . . . . . . . . . . . . 8DÐ230
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ231
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ232
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ235
Dome Light, Luggage Room Light, Courtesy Light and Map Light . . . . . . . . . . 8DÐ237
General Description . . . . . . . . . . . . . . . . . . 8DÐ237
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ238
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ240
Power Door Lock . . . . . . . . . . . . . . . . . . . . . . 8DÐ244 General Description . . . . . . . . . . . . . . . . . . 8DÐ244
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ245
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ250
Diagnosi s. . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ2 56
Power Window . . . . . . . . . . . . . . . . . . . . . . . 8DÐ261 General Description . . . . . . . . . . . . . . . . . . 8DÐ261
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ262
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ263
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ266
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ272