Isuzu 2000 Trooper UX Instruction manual

WORKSHOP MANUAL
TROOPER
(UX)
FOREWORD
Thismanualincludesspecialnotes,importantpoints,service
data, precautions, etc. that are needed for the maintenance,
adjustments, service, removal and installation of vehicle
components.
All information, illustrations and specifications contained in
this manual are based on the latest product information
available at the time of publication.
All rights are reserved to make changes at any time without
notice.
Arrangement of the material is shown in the table of contents
on the right-hand side of this page. A black spot on the first
page of each section can be seen on the edge of the book
below each section title. These point to a more detailed table
of contents preceding each section.
This manual applies to 2000 models.
SECTION TABLE OF CONTENTS
GENERAL INFORMATION
0A General Information
0B Maintenance and Lubrication
HEATING, VENTILATION AND AIR CONDITIONING
1A HVAC Systems
STEERING
2A Power Assisted System
SUSPENSION
3C Front Suspension
3D Rear Suspension
3E Wheel and Tire System
DRIVELINE/AXLE
4A1 Differential (Front)
4A2 Differential (Rear)
4B1 Driveline Control System (SHIFT ON THE FLY)
4B2 Driveline Control System (TOD)
4C Drive Shaft System
4D1 Transfer Case (Standard Type)
4D2 Transfer Case (TOD)
BRAKE
5A Brake Control System
5B Anti-Lock Brake System
5C Power-Assisted Brake System
5D Parking Brake System
ENGINE
6A Engine Mechanical
6B Engine Cooling
6C Engine Fuel
6D1 Engine Electrical
6D2 Ignition System
6D3 Starting and Charging System
6E Driveability and Emissions
6F Engine Exhaust
6G Engine Lubrication
6H Engine Speed Control System
6J Induction
TRANSMISSION
7A Automatic Transmission
7A1 Transmission Control System
7B Manual Transmission
7C Clutch
BODY AND ACCESSORIES
8A Lighting System
8B Wiper/Washer System
8C Entertainment
8D Wiring System
8E Meter and Gauge
8F Body Structure
8G Seats
8H Security and Locks
8I Sun Roof/Convertible Top
8J Exterior/Interior Trim
RESTRAINTS
9A Seat Belt System
9J Supplemental Restraint System (SRS)
9J1 Restraint Control System
CONTROL SYSTEM
10A Cruise Control System

0A–1
GENERAL INFORMATION
TROOPER GENERAL INFORMATION
CONTENTS
General Information 0A. . . . . . . . . . . . . . . . . . . . .
Maintenance and Lubrication 0B. . . . . . . . . . . . .
GENERAL INFORMATION
CONTENTS
General Repair Instruction 0A–1. . . . . . . . . . . . . . . .
Illustration Arrows 0A–2. . . . . . . . . . . . . . . . . . . . . . .
Identification 0A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Prevention Standard 0A–5. . . . . . . . . . . . . . . .
Lifting Instructions 0A–10. . . . . . . . . . . . . . . . . . . . . . .
Standard Bolts Torque Specifications 0A–13. . . . . .
Abbreviations Charts 0A–14. . . . . . . . . . . . . . . . . . . .
Service Parts Identification Plate 0A–15. . . . . . . . . .
General Repair Instruction
1.If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, “block” front or rear
wheels, set jack against the recommended lifting
points (see “Lifting Instructions” in this section), raise
vehicle and support with chassis stands and then
perform the service operations.
2.Before performing service operations, disconnect
groundcablefrom thebatterytoreducethechanceof
cable damage and burning due to short circuiting.
3.Use a cover on body, seats and floor to protect them
against damage and contamination.
4.Brake fluid and anti–freeze solution must be handled
with reasonable care, as they can cause paint
damage.
5.The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6.Use genuine Isuzu parts.
7.Used cotter pins, plastic clips, gaskets, O–rings, oil
seals, lock washers and self–locking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8.To facilitate proper and smooth reassembly
operation,keepdisassembledpartsneatlyingroups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9.Cleanthepartsbeforeinspectionorreassembly.Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10.Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
11.When necessary, use a sealer on gaskets to prevent
leakage.
12.Carefully observe all specifications for bolt and nut
torques.
13.When removing or replacing parts that require
refrigerant to be discharged from the air conditioning
system, be sure to use the Vehicle Refrigerant
Recovery and Recycling Equipment (VRRRE) to
recover and recycle Refrigerant–134a.
14.When a service operation is completed, make a final
check to be sure the service has been done properly
and the problem has been corrected.
15.SUPPLEMENTAL RESTRAINT SYSTEM
The vehicle is equipped with a Supplemental
Restraint System. (SRS)—Air Bag.
This system is not to be serviced without consulting
the appropriate service information.
Consult Sections 9J1 and 9J “SRS System” if work is
tobedone onthefront of thevehiclesuch asbumper,
sheet metal, seats, wiring, steering wheel or column.
Also review SRS system information if any arc
welding is to be done on the vehicle.
The SRS system equipped vehicle can be identified
by:
1. “AIR BAG” warning light on the instrument panel.
2. A Code “J” or “K” for fifth digit of vehicle
Identification Number.

0A–2 GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations.
Arrow Type Application
Front of vehicle
Up Side
Task Related
View Detall
View Angle
Dimension (1:2)
Sectioning (1:3)
Arrow Type Application
DAmbient/Clean air
flow
DCool air flow
DGas other than
ambient air
DHot air flow
DAmbient air mixed
with another gas
DCan indicate
temperature change
Motion or direction
Lubrication point oil or
fluid
Lubrication point grease
Lubrication point jelly

0A–3
GENERAL INFORMATION
Identification
Vehicle Identification Number (VIN)
Thisisthelegalidentificationofthevehicle.itislocatedon
the left bottom of the windshield. It can be easily seen
through the windshield from outside the vehicle.
905RY00002
F00RY00002

0A–4 GENERAL INFORMATION
Engine Serial Number
The gasoline engine serial number is stamped on the left
rear lower area of the cylinder block above the starter.
F06RW001
Transmission Serial Number
Manual : Stamped on the left side of the transmission
intermediate plate.
220RW084
Automatic : Stamped on the identification plate, located
on the left side of the transmission above the mode
switch.
240RW012

0A–5
GENERAL INFORMATION
Theft Prevention Standard
The 11 major components listed below will be marked
with 17 digit V.I.N. at the stage of production. In addition
its service parts will be marked with manufacturer’s trade
mark, “R” mark and “DOT” mark.
Reference
COMPONENT
INDICATION
Figure No.
COMPONENT
PRODUCTION SERVICE PARTS
0A-10 ENGINE 1– 6VE1 V.I.N. plate
0A-11 TRANSMISSION 2– Manual transmission
– Automatic transmission V.I.N. plate
0A-11 BODY 3– Engine hood
4– Front door
5– Rear door
6– Fender
7– Rear Quarter panel
8– Front bumper
9– Back door left side
10– Back door right side
11– Rear bumper
V.I.N. label
Anti Theft Stamping/Plate/Label
STAMPING/PLATE LABEL
PRODUCTION
SERVICE PARTS

0A–6 GENERAL INFORMATION
Anti Theft Stamping/Label/Plate Location
The stamping, label and plate locations are indicated by
arrows in the illustration below.
NOTE:
A. VIN plate locations for production.
B. Stamping locations for service parts.
Engine
901RW195
Manual Transmission (AR–5)
901RX021

0A–7
GENERAL INFORMATION
Automatic Transmission (THM)
901RW197
Body
901RW113
Legend
(3) Engine Hood
(4) Front Door
(5) Rear Door
(6) Fender
(7) Rear Quarfer Panel
(8) Front Bumper

0A–8 GENERAL INFORMATION
Body
901RW114
Legend
(9) Back Door Left Side (10) Back Door Right Side (11) Rear Bumper

0A–9
GENERAL INFORMATION
Body Label Instructions
Do not peel off the masking tape until completion of paint
workwhenreplacing these parts,asthetape is affixedon
the label attached to service parts for body of the
anti–theft component.
NOTE: Be sure to pull off the masking tape after paint
work has been completed.
Do not attempt to remove this label for any reason.
901RW083
Precautions in pulling off the masking tape
1.Use only your finger nail or a similar blunt instrument
topeeloffthemasking tape.Use ofa sharpobjectwill
damage the underlying anti–theft label.
2.Be careful not to damage the paint around the label.
901RY00057

0A–10 GENERAL INFORMATION
Lifting Instructions
CAUTION:
DIf a lifting device other than the original jack is used, it
is most important that the device be applied only to
the correct lifting points. Raising the vehicle from any
other point may result in serious damage.
DWhen jacking or lifting a vehicle at the frame side rail
or other prescribed lift points, be certain that lift pads
do not contact the catalytic converter, brake pipes or
cables, or fuel lines. Such contact may result in
damage or unsatisfactory vehicle performance.
Lifting Points and Supportable Point Locations
C00RW003

0A–11
GENERAL INFORMATION
Lifting Point; Front
DWhen using a floor jack, lift on the center of the skid
plate.
545RS001
Supportable Point; Front
DPositionthechassisstandsat thebottomoftheframe
sidemember, behind the front wheel.
501RS003
Lifting Point; Rear
DPosition the floor jack at the center of the rear axle
case when lifting the vehicle.
420RS002
Supportable Point; Rear
DPositionthechassisstandsat thebottomoftheframe
sidemember, just behind the trailing link bracket.
501RW002
Legend
(1) Trailing Link Bracket

0A–12 GENERAL INFORMATION
Supportable Point; Rear
DPosition the chassis stands at the bottom of the rear
axle case.
420RS001

0A–13
GENERAL INFORMATION
Standard Bolts Torque Specifications
The torque values given in the following table should be
applied where a particular torque is not specified.
Strength Class
4.8 8.8 9.8
Strength
Class
Refined Non-Refined
Bolt
Identification
Bolt Diameter ×
Pitch (mm)
M 6X1.0
M 8X1.25
M 10X1.25
* M10X1.5
M12X1.25
* M12X1.75
M14X1.5
* M14X2.0
M16X1.5
* M16X2.0
M18X1.5
M20X1.5
M22X1.5
M24X2.0
4—8 (3—6)
8—18 N·m (6—13 lb ft)
21—34 N·m (15—25 lb ft)
20—33 N·m (14—25 lb ft)
49—74 N·m (36—54 lb ft)
45—69 N·m (33—51 lb ft)
77—115 N·m (56—85 lb ft)
72—107 N·m (53—79 lb ft)
104—157 N·m (77—116 lb ft)
100—149 N·m (74—110 lb ft)
151—226 N·m (111—166 lb ft)
206—310 N·m (152—229 lb ft)
251—414 N·m (185—305 lb ft)
359—539 N·m (265—398 lb ft)
5—10 N·m (4—7 lb ft)
12—23 N·m (9—17 lb ft)
28—46 N·m (20—34 lb ft)
28—45 N·m (20—33 lb ft)
61—91 N·m (45—67 lb ft)
57—84 N·m (42—62 lb ft)
93—139 N·m (69—103 lb ft)
88—131 N·m (65—97 lb ft)
135—204 N·m (100—150 lb ft)
130—194 N·m (95—143 lb ft)
195—293 N·m (144—216 lb ft)
270—405 N·m (199—299 lb ft)
363—544 N·m (268—401 lb ft)
431—711 N·m (318—524 lb ft)
—
17—30 N·m (12—22 lb ft)
37—63 N·m (27—46 lb ft)
36—60 N·m (27—44 lb ft)
76—114 N·m (56—84 lb ft)
72—107 N·m (53—79 lb ft)
114—171 N·m (84—126 lb ft)
107—160 N·m (79—118 lb ft)
160—240 N·m (118—177 lb ft)
153—230 N·m (113—169 lb ft)
230—345 N·m (169—255 lb ft)
317—476 N·m (234—351 lb ft)
425—637 N·m (313—469 lb ft)
554—831 N·m (409—613 lb ft)
The asterisk * indicates that the bolts are used for
female–threaded parts that are made of soft materials
such as casting, etc.

0A–14 GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A — Ampere(s)
ABS — Antilock Brake System
AC — Alternating Current
A/C — Air Conditioning
ACCEL — Accelerator
ACC — Accessory
ACL — Air Cleaner
Adj — Adjust
A/F — Air Fuel Ratio
AIR — Secondary Air Injection System
Alt — Altitude
AMP — Ampere(s)
ANT — Antenna
ASM — Assembly
A/T — Automatic Transmission/Transaxle
ATDC — After Top Dead Center
ATF — Automatic Transmission Fluid
Auth — Authority
Auto — Automatic
BARO — Barometric Pressure
Bat — Battery
B+ — Battery Positive Voltage
Bbl — Barrel
BHP — Brake Horsepower
BPT — Backpressure Transducer
BTDC — Before Top Dead Center
°C — Degrees Celsius
CAC — Charge Air Cooler
Calif — California
cc — Cubic Centimeter
CID — Cubic Inch Displacement
CKP — Crankshaft Position
CL — Closed Loop
CLCC — Closed Loop Carburetor Control
CMP — Camshaft Position
CO — Carbon Monoxide
Coax — Coaxial
Conn — Connector
Conv — Converter
Crank — Crankshaft
Cu. In. — Cubic Inch
CV — Constant Velocity
Cyl — Cylinder(s)
DI — Distributor Ignition
Diff — Differential
Dist — Distributor
DLC — Data Link Connector
DOHC — Double Overhead Camshaft
DTC — Diagnostic Trouble Code
DTM — Diagnostic Test Mode
DTT — Diagnostic Test Terminal
DVM — Digital Voltmeter (10 meg.)
DVOM — Digital Volt Ohmmeter
EBCM — Electronic Brake Control Module
ECM — Engine Control Module
ECT — Engine Coolant Temperature
EEPROM — Electronically Erasable Programmable
Read Only Memory
EGR — Exhaust Gas Recirculation
EI — Electronic Ignition
ETR — Electronically Tuned Receiver
EVAP — Evaporation Emission
Exh — Exhaust
°F — Degrees Fahrenheit
Fed — Federal (All States Except Calif.)
FF — Front Drive Front Engine
FL — Fusible Link
FLW — Fusible Link Wire
FP — Fuel Pump
FRT — Front
ft — Foot
FWD — Front Wheel Drive
4WD — Four Wheel Drive
4 x 4 — Four Wheel Drive
4 A/T — Four Speed Automatic Transmission/Transaxle
Gal — Gallon
GEN — Generator
GND — Ground
Gov — Governor
g — Gram
Harn — Harness
HC — Hydrocarbons
HD — Heavy Duty
Hg — Hydrargyrum (Mercury)
HiAlt — High Altitude
HO2S — Heated Oxygen Sensor
HVAC — Heater–Vent–Air–Conditioning
IAC — Idle Air Control
IAT — Intake Air Temperature
IC — Integrated Circuit / Ignition Control
ID — Identification / Inside Diameter
IGN — Ignition
INJ — Injection
IP — Instrument Panel
IPC — Instrument Panel Cluster
Int — Intake
ISC — Idle Speed Control
J/B — Junction Block
kg — Kilograms
km — Kilometers
km/h — Kilometer per Hour
kPa — Kilopascals
kV — Kilovolts (thousands of volts)
kW — Kilowatts
KS — Knock Sensor
L — Liter
lb ft — Foot Pounds
lb in — Inch Pounds
LF — Left Front
LH — Left Hand
LR —Left Rear
LS — Left Side
LWB — Long Wheel Base
L–4 — In–Line Four Cylinder Engine
MAF — Mass Air Flow
MAN — Manual
MAP — Manifold Absolute Pressure
Max — Maximum
MC — Mixture Control
MFI — Multiport Fuel Injection
MIL — Malfunction Indicator Lamp
Min — Minimum
mm — Millimeter
MPG — Miles Per Gallon
MPH — Miles Per Hour
M/T — Manual Transmission/Transaxle
MV — Millivolt

0A–15
GENERAL INFORMATION
N — Newtons
NA — Natural Aspirated
NC — Normally Closed
N·M — Newton Meters
NO — Normally Open
NOX — Nitrogen, Oxides of
OBD — On-Board Diagnostic
OD — Outside Diameter
O/D — Over Drive
OHC — Overhead Camshaft
OL — Open Loop
O2 — Oxygen
O2S — Oxygen Sensor
PAIR — Pulsed Secondary Air Injection System
P/B — Power Brakes
PCM — Powertrain Control Module
PCV — Positive Crankcase Ventilation
PRESS — Pressure
PROM — Programmable Read Only Memory
PNP — Park/Neutral Position
P/S — Power Steering
PSI — Pounds per Square Inch
PSP — Power Steering Pressure
Pt. — Pint
Pri — Primary
PWM — Pulse Width Modulate
Qt. — Quart
REF — Reference
RF — Right Front
RFI — Radio Frequency Interference
RH — Right Hand
RPM — Revolutions Per Minute
RPM Sensor — Engine Speed Sensor
RPO — Regular Production Option
RR — Right Rear
RS — Right Side
RTV — Room Temperature Vulcanizing
RWAL — Rear Wheel Antilock Brake
RWD — Rear Wheel Drive
SAE — Society of Automotive Engineers
Sec — Secondary
SFI — Sequential Multiport Fuel Injection
SI — System International
SIR — Supplemental Inflatable Restraint System
SOHC — Single Overhead Camshaft
Sol — Solenoid
SPEC — Specification
Speedo — Speedometer
SRS — Supplemental Restraint System
ST — Start / Scan Tool
Sw — Switch
SWB — Short Wheel Base
SYN — Synchronize
Tach — Tachometer
TB — Throttle Body
TBI — Throttle Body Fuel Injection
TCC — Torque Converter Clutch
TCM — Transmission Control Module
TDC — Top Dead Center
Term — Terminal
TEMP — Temperature
TOD— Torque On Demand
TP — Throttle Position
TRANS — Transmission/Transaxle
TURBO — Turbocharger
TVRS — Television & Radio Suppression
TVV — Thermal Vacuum Valve
TWC — Three Way Catalytic Converter
3A/T—ThreeSpeedAutomaticTransmission/Transaxle
2WD — Two Wheel Drive
4 x 2 — Two Wheel Drive
U–joint — Universal Joint
V — Volt(s)
VAC — Vacuum
VIN — Vehicle Identification Number
VRRRE — Vehicle Refrigerant Recovery and Recycling
Equipment
V–ref — ECM Reference Voltage
VSS — Vehicle Speed Sensor
VSV — Vacuum Switch Valve
V–6 — Six Cylinder “V” Engine
V–8 — Eight Cylinder ”V” Engine
W — Watt(s)
w/ — With
w/b — Wheel Base
w/o — Without
WOT — Wide Open Throttle
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.
905RW007

0B–1
MAINTENANCE AND LUBRICATION
TROOPER GENERAL INFORMATION
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule List 0B–1. . . . . . . . . . . . . . .
Explanation of Complete Vehicle Maintenance
Schedule 0B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants 0B–8. . . .
Lubricant Viscosity Chart 0B–9. . . . . . . . . . . . . . . . .
Recommended Liquid Gasket 0B–11. . . . . . . . . . .
Recommended Thread Locking Agents 0B–12. . .
Maintenance Service Data 0B–13. . . . . . . . . . . . . . . .
Maintenance Schedule List
Normal Vehicle Use
The maintenance instructions in this Maintenance
Schedule are based on the assumption that the vehicle
will be used as designed:
Dto carry passengers and cargo within the limitations
specified on the tire placard located on the inside of
the glove compartment door;
Dto be driven on reasonable road surfaces within legal
operating limits;
Dto be driven on a daily basis, as a general rule, for at
least several miles/kilometers;
Dto be driven on unleaded fuel
Unusual or severe operating conditions will require more
frequent vehicle maintenance, as specified in the
following sections.
Severe Driving Conditions
If the vehicle is usually operated under any of the severe
drivingconditionslistedbelow,itisrecommendedthatthe
applicable maintenance services be performed at the
specified interval shown in the chart below.
Severe driving conditions:
DTowing a trailer, using a camper or car top carrier.
DRepeated short trips of less than 8 km (5 miles) with
outside temperature remaining below freezing.
DExtensive idling and/or low speed driving for long
distances, such as police, taxi or door-to-door
delivery use.
DOperating on dusty, rough, muddy or salt spread
roads.
ITEMS INTERVAL
REPLACE TIMING BELT Every 75,000 miles (120,000 km)
CHANGE ENGINE OIL AND OIL FILTER Every 3,000 miles (4,800 km) or 3 months
CHANGE AUTOMATIC TRANSMISSION FLUID Every 20,000 miles (32,000 km)
CHANGE FRONT AND REAR AXLE OIL Every 15,000 miles (24,000 km)
CHANGE POWER STEERING FLUID Every 30,000 miles (48,000 km)

0B–2 MAINTENANCE AND LUBRICATION
Mileage Only Items

0B–3
MAINTENANCE AND LUBRICATION
Mileage/Months

0B–4 MAINTENANCE AND LUBRICATION