Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993))

Factory Workshop Manual Make Isuzu Model Trooper (2 Door) Engine and year V6-3165cc 3.2L SOHC (6VD1) (1993) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > System Information > System Diagnosis Codes by System: Testing and Inspection For diagnosis of all P codes Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Testing and Inspection Brake Fluid Pump Relay: Testing and Inspection CHART C "ANTILOCK" Warning Light "ON" approx. 15 Seconds later after Starting Engine with Vehicle Stationary (Motor Relay Circuit Faulty) Circuit Operation The signal from the Electronic Brake Control Module (EBCM) causes the motor relay to turn ON/OFF, the motor to rotate and the pump to operate. When opens or shorts occur in this circuit, the "ANTILOCK" light comes on and the Antilock Brake System (ABS) is shut off approx. 15 seconds after starting the engine while at idle. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Testing and Inspection > Page 11 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Solenoid Valve Relay > Component Information > Testing and Inspection Brake Fluid Solenoid Valve Relay: Testing and Inspection CHART B-5 VALVE RELAY CIRCUIT Circuit Operation The signal from the Electronic Brake Control Module (EBCM) causes the valve relay to turn ON/OFF, and establishes the power circuit for the solenoid valve. When opens or shorts occur in this circuit, or when the relay is defective, the "ANTILOCK" light comes on, and the Antilock Brake System (ABS) system is shut off. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Solenoid Valve Relay > Component Information > Testing and Inspection > Page 15 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions Electronic Brake Control Module: Diagram Information and Instructions Circuit Schematics CIRCUIT APPLICATION Circuit schematics break the entire electrical system into individual circuits. Electrical components that work together are shown together. CURRENT FLOW Each drawing is arranged so current flows from positive, at top of page to ground, at bottom. The "hot" labels at the top of a fuse indicate when the ignition switch supplies power to that fuse. CIRCUIT NETWORKING Wires that connect to another circuit are shown with an arrowhead pointing in the direction of current flow. The name of the circuit that shares the wiring is shown for reference. POWER AND GROUND SUPPLY "See Fuse Box Details" indicates there are connections to other circuits that are not shown. All shared circuits are shown on the Fuse Box Details schematic. "See Ground Distribution" indicates there are shared ground circuits which are shown on the ground distribution schematic. CIRCUIT/COMPONENT LOCATION No attempt is made to represent the location or proximity of components. If a wire is actually 4 foot or 4 inches, it will be represented without regard in the schematic. Component/Connector Location and I.D. COMPONENT AND CONNECTOR LOCATION Supplied with the wiring schematic is a component location index. The index lists the correct photograph for the components and connectors listed. The photographs are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. HARNESS ROUTING Harness routing and selected connectors related to the system are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. CONNECTOR I.D. All connectors with more than 2 terminals are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. Fuse Box Details The fuse box details schematic shows all the wiring between a fuse and the components connected to the output side of the fuse. It shows what supplies power to the fuse and when it is energized. Ground Distribution The ground distribution schematics show which components share a common ground point. This information can be very helpful in diagnosing inoperative circuits. If more than one components are not working and they share a common ground, it is likely the ground circuit is faulty. However, if one of the circuits is operative and the other is not, you know the ground and the wire are good up to a splice. Light Switch Details The light switch details schematic shows all the wiring between the light switch/relays and the components connected to the output side of the light switch/relays. Power Distribution The Power distribution schematic shows the wiring from the battery and alternator to the: - Starter solenoid - Fuse box - Light switch - Ignition switch - Fuse link The first component after a fuse link is shown. In certain instances, the first component after a fuse box, fuse and light switch is shown. All fuses in the schematic are "Hot At All Times", since battery voltage is the direct source. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 21 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 22 Symbol Identification Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Clear: CLR Gray: GRY Green: GRN Light Blue: LT BLU Light Green: LT GRN Orange: ORN Pink: PNK Red: RED Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 23 White: WHT Yellow: YEL Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 24 Electronic Brake Control Module: Diagnostic Aids Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 25 Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 26 testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 27 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Voltage Check Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 28 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 29 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 30 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 31 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 32 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 33 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 34 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 35 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 36 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 37 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 38 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 39 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 40 Electronic Brake Control Module: Electrical Diagrams Fig. 47 RWAL wiring diagram. W/RWAL Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 41 Fig. 66 4 wheel ABS wiring diagram. W/4 Wheel ABS Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Four Wheel Antilock Brakes Electronic Brake Control Module: Description and Operation Four Wheel Antilock Brakes ELECTRONIC BRAKE CONTROL MODULE (EBCM) The EBCM monitors the speed of each wheel to determine if any wheel is beginning to lock. If a locking condition is detected, brake pressures are automatically adjusted to provide for maximum stopping without wheel lock. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 44 Electronic Brake Control Module: Description and Operation Rear Wheel Antilock Brakes ELECTRONIC BRAKE CONTROL MODULE (EBCM) The electronic brake control module is microprocessor based and is located on the front end of the center console. It performs three different algorithms to calculate excessive wheel deceleration and performs self check diagnostics. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Page 45 Electronic Brake Control Module: Testing and Inspection PIN-OUT CHECKS - Connect Pinout Box and J-35592 to 35-Pin Electronic Brake Control Module connector. - Perform checks with high impedance digital multimeter J-34029A or equivalent Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Rear Wheel Antilock Brakes Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brakes REAR WHEEL ANTILOCK ELECTRONIC BRAKE CONTROL MODULE (EBCM) REPLACEMENT REMOVAL 1. Center console - To remove the center console box, refer to Instrument Panel. 2. EBCM harness connector 3. EBCM 4. EBCM cover 5. Bonding cable 6. EBCM ground cable INSTALLATION 6. EBCM ground cable 5. Bonding cable 4. EBCM cover - After installation of the EBCM cover, apply soft tape to the EBCM bracket to protect the harness from damage. 3. EBCM 2. EBCM harness connector 1. Center console Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Rear Wheel Antilock Brakes > Page 48 Electronic Brake Control Module: Service and Repair 4 Wheel Antilock Brakes ELECTRONIC BRAKE CONTROL MODULE (EBCM) REMOVAL Remove the center console. 1. EBCM fixing bolts 2. EBCM wiring connector INSTALLATION 2. EBCM wiring connector 1. EBCM fixing bolts - Tighten the EBCM fixing bolts to the specified torque. Torque: 8 N.m (69 in.lb.) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 55 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Blower, A/C, Thermostat and Compressor Relay Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Blower, A/C, Thermostat and Compressor Relay > Page 60 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Testing and Inspection Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Spark Control Module > Component Information > Description and Operation Electronic Spark Control Module: Description and Operation KS Circuit PURPOSE Provides a signal to the ECM when engine detonation occurs. LOCATION Knock sensor is mounted in engine block under intake manifold. The solid state module is near the upper R.H. corner of the inner fender. OPERATION When abnormal engine vibrations (spark knock) are present, sensor produces voltage signal which is received by knock sensor (KS) module. As long as KS module sees no voltage from knock sensor, KS sends a signal voltage (8 to 10 volts) to ECM which in turn provides normal spark advance. When the sensor detects a knock is generates voltage. When the KS module receives this voltage it reduce the signal to the ECM to O volts. The ECM then retards the ignition timing. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 82 Engine Control Module: Description and Operation Inputs And Outputs PURPOSE Control unit of fuel injection system. LOCATION Under instrument panel in front of the center console OPERATION It constantly looks at information from various sensors, and controls systems that affect vehicle performance. ECM also performs diagnostic function of system. It can recognize operational problems, alert driver through "Check Engine" light, and store a code or codes which identify problem areas to aid technician in making repairs. ECM supplies either 5 or 12 volts to power various sensors or switches and controls output circuits such as fuel injectors, IAC valve, A/C clutch relay, etc. by controlling ground circuit through transistors or a "quad-driver". Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 83 Engine Control Module: Service and Repair ECM REMOVAL - Negative battery cable - Lower trim panel at console (4 fasteners) - Air Conditioning Heater transfer tube - ABS controller electrical connector (1) (if equipt) - ABS controller (4 fasteners) (if equipt) - Four (4) fasteners for ECM bracket - ECM electrical connectors (2) - ECM from 'inder dash, bracket still attached NOTE: To prevent possible Electronic Discharge damage to the ECM, Do not touch the connector pins or soldered components on the circuit board. INSTALLATION - ECM and bracket under dash - Four (4) fasteners and tighten - Two (2) ECM electrical connectors - ABS controller and four (4) fasteners (if equipt) - ABS controller electrical connector (if equipt) - Air Conditioning Heater transfer tube - Lower trim panel at console (4 fasteners) - Negative battery cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 91 Relay Location Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 92 Fuel Pump Relay: Description and Operation Fuel Pump Circuit PURPOSE Allows the ECM control over fuel pump operation. Fuel Pump Relay Connector LOCATION In the fuse/relay center, in the engine compartment. OPERATION When ignition is switched "RUN" position (engine not running), ECM energizes fuel pump relay for two seconds, causing fuel pump to pressurize fuel system. If ECM does not receive ignition reference pulses (engine cranking or running) within two seconds, it will de-energize relay, stopping fuel pump. After the engine starts, the ECM uses the signal from the electronic ignition module to determine if the engine is running. If the signal is interrupted, the ECM will not energize the fuel pump. This prevents the fuel from operating when the engine is not running. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 93 Fuel Pump Relay: Testing and Inspection Fuel Pump Circuit Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 94 Chart A-5 Fuel Pump Relay Circuit Circuit Description When the ignition switch is turned "ON", the Engine Control Module (ECM) will activate the fuel pump relay and operate the in tank fuel pump. The fuel pump will operate as long as the engine is cranking or running and the ECM is receiving ignition reference pulses. If there are no reference pulses, the ECM will shut "OFF" the fuel pump within 2 seconds after key "ON". Test Description Numbers below refer to circled numbers on the diagnostic chart. 1. Checks for the presence Battery Position Voltage at switching portion of fuel pump relay. 2. Checks circuit between fuel pump relay and ground (including the fuel pump). 3. This test will confirm if voltage is available to the relay coil. Diagnostic Aids A visual inspection of wiring and connectors should be made if an intermittent problem exists. For further information, refer to Intermittent Check Procedure. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Electronic Spark Control Module > Component Information > Description and Operation Electronic Spark Control Module: Description and Operation KS Circuit PURPOSE Provides a signal to the ECM when engine detonation occurs. LOCATION Knock sensor is mounted in engine block under intake manifold. The solid state module is near the upper R.H. corner of the inner fender. OPERATION When abnormal engine vibrations (spark knock) are present, sensor produces voltage signal which is received by knock sensor (KS) module. As long as KS module sees no voltage from knock sensor, KS sends a signal voltage (8 to 10 volts) to ECM which in turn provides normal spark advance. When the sensor detects a knock is generates voltage. When the KS module receives this voltage it reduce the signal to the ECM to O volts. The ECM then retards the ignition timing. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Coil Pack Under ignition coil pack, at front of engine. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Electrical Test Equipment Air Bag Control Module: Service Precautions Electrical Test Equipment When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Inserting the probe into the terminal side of the connector, and tampering the connector could cause malfunction of the SRS system or an error in inspection. Use a probe with the correct tip. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using tools which are not specified standard design could cause an error in inspection due to poor metal-to-metal contact. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Electrical Test Equipment > Page 110 Air Bag Control Module: Service Precautions Wiring Never attempt to modify, splice or repair SRS wiring. NOTE: SRS wiring can be identified by special yellow outer protective covering. Be sure to install the harness wires so that they are not pinched or interfering with other parts. Make sure all SRS ground locations are clean and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 111 Air Bag Control Module: Description and Operation Deployment Loop and Sensing and Diagnostic Module The deployment loop and Sensing and Diagnostic Module (SDM) are the two main portions of the Supplemental Restraint System (SRS). The deployment loop portion supplies current through the SRS modules, which are used to deploy the air bags in the event of a front end collision of sufficient force up to 30 ° off vehicle centerline. Fig. 2 Deployment Loop Diagram The deployment loop consists of the arming sensor, SRS coil, inflator modules and discriminating sensors, Fig. 2. The arming sensor switches power to the inflator modules on the deployment loop high side. Either of the discriminating sensors may provide ground to the inflator modules on the deployment loop low side. The modules will only be supplied sufficient current to deploy when the arming sensor and at least one of the two discriminating sensors closes simultaneously for three milliseconds or more. The Sensing and Diagnostic Module (SDM) contains a 24 Volt Loop Reserve (24 VLR) and a sensing device to convert vehicle velocity changes to electrical signals. These are processed by the SDM and compared to a value stored in memory. If the generated signal exceeds the stored value, the SDM Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 112 sends current flow to the air bags and deploys them. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 113 Air Bag Control Module: Testing and Inspection To ensure proper system operation on any vehicle involved in a collision, all system components should be inspected for dents, cracks, exposure to excessive heat and other damage even if deployment did not take place. The steering column, knee pad and instrument panel reinforcement plate should be inspected for damage. All air bag system wiring should be checked for chaffing and interference with other vehicle components. Do not attempt to repair forward discriminating sensor, passenger compartment discriminating sensor, arming sensor, DERM, coil assembly, SIR module or mounting brackets. If found to be damaged, replace with a new unit. To ensure proper operation of the SIR system, the vehicle structure must be returned to its original configuration. When repairing vehicle, the SIR system should be disarmed as outlined under Technician Safety Information. Also, when performing service procedure, do not expose components or wiring to heat guns, welding or spray guns. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification Control Module: Technical Service Bulletins A/T - (4L30E) Control Module Identification BULLETIN NUMBER SB96-05-L001 ISSUE DATE JANUARY 1996 GROUP TRANSMISSION 4L30-E AUTOMATIC TRANSMISSION/TRANSMISSION CONTROL MODULE IDENTIFICATION CHART AFFECTED VEHICLES 1990-91 Trooper II (KT), 1992-95 Trooper (UX), 1991-95.5 Rodeo (UC) models equipped with 4L30-E automatic transmission. SERVICE INFORMATION When replacing 4L30-E automatic transmissions or transmission control modules (TCMs), it is important to order the appropriate replacement parts. Failure to pair the proper TCM or transmission with its proper counterpart can result in poor transmission performance. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification > Page 120 This Service Bulletin provides important identification data to ensure that a proper pairing of transmission and TCM is always made. Figures 1 through 3 show the typical location of the identification plate on both the transmission and TCM. Figure 1 shows the typical location on transmissions and TCMs manufactured by Bosch for 1990-93 MY vehicles. Figures 2 and 3 show the typical location on transmissions and TCMs manufactured by Delco Electronics for 1994 and 1995-95.5 MY vehicles respectively. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification > Page 121 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification > Page 122 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification > Page 123 The chart provides an extensive listing of 4L30-E automatic transmissions and their TCM counterparts. When ordering a replacement part, use the chart as shown: ^ Select the appropriate vehicle model, applied date, and engine type in the APPLICATION column. ^ Read the listed transmission model code(s) for that application in the TRANSMISSION MODEL CODE column. ^ Read the actual AIPDN part number for that transmission in the TRANSMISSION PART NUMBER column. ^ Read the proper TCM model code(s) for that application in the TCM MODEL CODE column. ^ Read the actual AIPDN part number for that TCM in the TCM PART NUMBER column. For parts ordering information, refer to AIPDN Technical Bulletin AIPDN-TEC-LV1-96. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 124 Control Module: Locations Beneath left side of instrument panel, behind kick panel. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 125 Control Module: Description and Operation PURPOSE The Transmission Control Module (TCM), based on predetermined shifting characteristics and lockup operating valve, provides optimum shifting control across the range of vehicle operating conditions. OPERATION The following input signals are sent to the TCM: select lever position from the mode switch, running mode from the power and winter switches, throttle opening from the throttle position sensor, vehicle speed from the vehicle speed sensor, and engine rpm from the ECM. After receiving these signals, the TCM determines vehicle running condition and sends output signals to each solenoid to control shifting. - When the TCC solenoid is engaged, the lockup mechanism operates. - Shift solenoids 2/3 and 1-2/3-4 select shift gear position. - The force motor controls line pressure to improve shift feel. When the TCM detects an abnormal signal, it causes the CHECK TRANS lamp on the instrument panel to flash, alerting the driver to a malfunction. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation The standard master cylinder is equipped with a fluid level sensor located in the reservoir. This sensor will activate the red ``Brake'' lamp if a low fluid condition is detected. Once the fluid level is corrected the lamp will go out. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Deceleration Sensor <--> [Lateral Accelerometer] > Component Information > Description and Operation Deceleration Sensor: Description and Operation G-SENSOR The G-sensor installed inside the center console detects the vehicle deceleration speed and sends a signal to the EBCM. It is normally on, and is turned off when the vehicle deceleration speed exceeds about 0.35G. In the 4WD vehicle, all four wheels may be decelerated in almost the same phase, since all wheels are connected on the driver's side. This tendency is noticeable particularly on roads with low friction coefficient, and the ABS control is adversely affected. The G-sensor judges whether the friction coefficient of road surface is low or high, and changes the operating system to ensure ABS control. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Deceleration Sensor <--> [Lateral Accelerometer] > Component Information > Description and Operation > Page 145 Deceleration Sensor: Service and Repair G-SENSOR REMOVAL 1. Center console 2. G-sensor wiring connector 3. G-sensor fixing bolt 4. G-sensor INSPECTION AND REPAIR 1. Place the G-sensor on a level surface, and check the G-sensor for continuity between terminals. ^ If no continuity, replace with a new one. 2. Check the G-sensor for continuity when it is inclined by 30°. ^ If continuity, replace with a new one. INSTALLATION 4. G-sensor - Care should be taken so that the G-sensor is not installed in the wrong direction. 3. G-sensor fixing bolt - Tighten the fixing bolt to the specified torque. Torque: 6 N.m (53 in.lb.) 2. G-sensor wiring connector 1. Center console Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes WHEEL SPEED SENSOR It consists of a sensor and a rotor. The sensor is attached to the knuckle on the front wheels and to the axle shaft bearing holder on the rear wheels. The rotor is press-fit in the axle shaft on the front and rear wheels respectively. The flux generated from electrodes magnetized by a magnet in the sensor varies due to rotation of the rotor, and the electromagnetic induction generates alternating voltage in the coil. This voltage draws a "sine curve" with the frequency proportional to rotor speed and it allows detection of wheel speed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 150 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes SPEED SENSOR The speed sensor is single pole, variable reluctance pick up, mounted in the rear differential carrier. An exciter ring is press fit on the differential ring gear and provides the signal for the sensor. The signal generated is proportional to the average speed of the rear wheels and is used by the electronic brake control module (EBCM) to determine locking tendencies of the rear wheels. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 151 Wheel Speed Sensor: Testing and Inspection Refer to Antilock Brakes / Traction Control Systems/Testing and Inspection for testing information for this component. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Four Wheel Antilock Brakes Wheel Speed Sensor: Service and Repair Four Wheel Antilock Brakes Front Wheel Speed Sensor FRONT SPEED SENSOR REMOVAL 1. Speed sensor connector 2. Sensor cable fixing bolt (Upper side) 3. Sensor cable fixing bolt (Lower side) 4. Sensor fixing bolt 5. Speed sensor INSPECTION AND REPAIR - Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc. - Check the pole piece for damage; replace speed sensor if necessary. - Check the speed sensor cable for short or open circuit, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. - Check the sensor ring for damage including tooth chipping, and if damaged, replace the sensor ring assembly. INSTALLATION 5. Speed sensor - Take care not to hit the pole piece speed sensor during installation. 4. Speed sensor fixing bolt - Tighten the fixing bolt to the specified torque. Torque: 8 N.m (69 in.lb.) 3. Speed sensor cable fixing bolt (Lower side) - Tighten the fixing bolt to the specified torque. Torque: 24 N.m (18 in.lb.) 2. Speed sensor cable fixing bolt (Upper side) - Tighten the fixing bolt to the specified torque. Torque: 6 N.m (52 in.lb.) - Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 1. Speed sensor connector Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Four Wheel Antilock Brakes > Page 154 Rear Wheel Speed Sensor REAR SPEED SENSOR REMOVAL 1. Speed sensor connector 2. Clip (11 pieces) 3. Sensor cable fixing bolt 4. Sensor fixing bolt 5. Speed sensor INSPECTION AND REPAIR - Check speed sensor pole piece for presence of foreign materials; remove any dirt, etc. - Check the pole piece for damage, and replace speed sensor if necessary. - Check speed sensor cable for short or open, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. - Check the sensor ring for damage including tooth chipping, and if damaged replace the axle shaft assembly. INSTALLATION 5. Speed sensor - Take care not to hit the speed sensor pole piece during installation. 4. Sensor fixing bolt - Tighten the fixing bolt to the specified torque. Torque: 18 N.m (13 ft.lb.) 3. Sensor cable fixing bolt - Tighten the fixing bolt to the specified torque. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Four Wheel Antilock Brakes > Page 155 Torque: 24 N.m (18 ft.lb.) - Confirm that the cable is not twisted when connecting the speed sensor cable. 2. Clip (11 pieces) 1. Speed sensor connector Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Four Wheel Antilock Brakes > Page 156 Wheel Speed Sensor: Service and Repair Rear Wheel Antilock Brakes SPEED SENSOR REPLACEMENT NOTE: The speed sensor is not serviceable. It should be replaced when necessary. REMOVAL 1. Harness connector 2. Bolt 3. Speed sensor INSTALLATION To install, follow the removal steps in the reverse order, noting the following points; 1. Tighten the bolt to the specified torque. Bolt Torque: 24 N.m (18 ft.lb) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Temperature ........................................................................................................................................ ............................................................... Resistance -18°C (0°F) .......................................................................................................................................... .................................................................. 25K ohms -7°C (20°F) ...................................................... ................................................................................................................................................... 13.5K ohms 4°C (40°F) .................................................................................................................................. .......................................................................... 7.5K ohms 20°C (68°F) ............................................ .............................................................................................................................................................. 3.4K ohms 38°C (100°F) ..................................................................................................................... ................................................................................... 1.8K ohms 70°C (160°F) ................................. .............................................................................................................................................................. ........... 450 ohms 100°C (212°F) ......................................................................................................... ............................................................................................... 185 ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 162 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 163 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature Sensor ECT Sensor PURPOSE Provides engine temperature information to the Engine Control Module (ECM). LOCATION Rear of engine. OPERATION The ECM supplies a 5V signal to the sensor and measures voltage variation. By measuring this variation, the ECM measures coolant temperature. This input is a factor in calculations involving most ECM controlled systems. CONSTRUCTION The coolant temperature sensor is a thermistor (a device whose resistance changes with temperature) mounted in the engine cooling system. Low temperature produces high resistance (100K ohms at -40°C / -40°F) while high temperature produces low resistance (70 ohms at 130°C / 266°F). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 164 Engine Temperature Sensor: Service and Repair ECT Sensor REMOVAL NOTE: Care must be taken when handling Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. - Negative battery cable. - Drain engine coolant system. - Intake manifold assembly. Refer to Fuel Delivery and Air Induction. - Electrical connector - ECT sensor. Remove from rear of engine coolant transfer tube. INSTALLATION - ECT sensor. Apply sealer or equivalent to threads only. - Tighten the ECT sensor to the specified torque Torque 30 N-m (22 lb-ft) - ECT sensor connector - Intake manifold assembly - Negative battery cable. - Refill engine coolant system. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection 1. Ensure there is continuity between connectors with clutch pedal depressed. 2. Ensure there is no continuity between connectors with clutch pedal released. 3. If continuity is not as specified, replace the switch. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise and Stop Switch Cruise Control Switch: Testing and Inspection Cruise and Stop Switch Fig. 8 Cruise & Stop Switch Inspection 1. Check continuity between switch terminals as shown in Fig. 8. 2. If continuity is not as indicated, replace switch. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise and Stop Switch > Page 173 Cruise Control Switch: Testing and Inspection Main, Set and Resume Switch Fig. 10 Main, Set & Resume Switch Inspection 1. Disconnect two satellite switch connectors and check continuity between the switch side connector terminals as shown in Fig. 10. 2. If continuity is not as indicated, replace switch. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Testing and Inspection > Analog Meter Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection Analog Meter Fig. 11 Speed Sensor Inspection W/Analog Tester 1. Connect a circuit tester to meter terminals No. C102-4 and C103-10, Fig. 11. 2. Turn the inner shaft of speedometer slowly and ensure tester indicates a continuity four times per revolution. If continuity is not as specified, replace speedometer. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Testing and Inspection > Analog Meter > Page 178 Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection Digital Meter Fig. 12 Speed Sensor Inspection W/Digital Tester 1. Disconnect vehicle speed sensor to meter subassembly electrical connector, Fig. 12. Fig. 13 Speed Sensor To Circuit Tester 2. Connect yellow lead of the connector to 5V power source and the blue lead to ground, Fig. 13. 3. Connect the green lead to the positive lead of the circuit tester and the negative lead to ground. 4. Turn the inner shaft of speedometer slowly and ensure tester indicates a continuity four times per revolution. If continuity is not as specified, replace the speedometer. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > A/C Thermostat - Manual Correction Evaporator Temperature Sensor / Switch: Technical Service Bulletins A/C Thermostat - Manual Correction BULLETIN NUMBER SB93-12-005 ISSUE DATE December 1993 GROUP AIR CONDITIONING 1993 A/C THERMOSTAT (WORKSHOP MANUAL CORRECTION) AFFECTED VEHICLES 1993 Trooper (UX), Rodeo (UC), Pickup (TF) and Amigo (TC) models equipped with air conditioning. SERVICE INFORMATION The air conditioning electronic thermostat and thermostat removal procedures for affected vehicles are incorrectly described in the Workshop Manuals: Affected vehicles may be equipped with either of the following two different types of A/C electronic thermostat: BRACKET TYPE: The thermostat is built into a bracket, which can be removed without refrigerant recovery and evaporator removal. CLIP TYPE: The thermostat can only be removed after the refrigerant is recovered and the evaporator is removed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > A/C Thermostat - Manual Correction > Page 190 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > A/C Thermostat - Manual Correction > Page 191 This Service Bulletin contains corrected A/C thermostat descriptions and service procedures for affected vehicles. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 192 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Gauge Tank Unit Located on right side under vehicle. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 200 Fuel Gauge Tank Unit Replacement Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Light Switch Details (Component Location Index) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Circuit Schematics CIRCUIT APPLICATION Circuit schematics break the entire electrical system into individual circuits. Electrical components that work together are shown together. CURRENT FLOW Each drawing is arranged so current flows from positive, at top of page to ground, at bottom. The "hot" labels at the top of a fuse indicate when the ignition switch supplies power to that fuse. CIRCUIT NETWORKING Wires that connect to another circuit are shown with an arrowhead pointing in the direction of current flow. The name of the circuit that shares the wiring is shown for reference. POWER AND GROUND SUPPLY "See Fuse Box Details" indicates there are connections to other circuits that are not shown. All shared circuits are shown on the Fuse Box Details schematic. "See Ground Distribution" indicates there are shared ground circuits which are shown on the ground distribution schematic. CIRCUIT/COMPONENT LOCATION No attempt is made to represent the location or proximity of components. If a wire is actually 4 foot or 4 inches, it will be represented without regard in the schematic. Component/Connector Location and I.D. COMPONENT AND CONNECTOR LOCATION Supplied with the wiring schematic is a component location index. The index lists the correct photograph for the components and connectors listed. The photographs are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. HARNESS ROUTING Harness routing and selected connectors related to the system are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. CONNECTOR I.D. All connectors with more than 2 terminals are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. Fuse Box Details The fuse box details schematic shows all the wiring between a fuse and the components connected to the output side of the fuse. It shows what supplies power to the fuse and when it is energized. Ground Distribution The ground distribution schematics show which components share a common ground point. This information can be very helpful in diagnosing inoperative circuits. If more than one components are not working and they share a common ground, it is likely the ground circuit is faulty. However, if one of the circuits is operative and the other is not, you know the ground and the wire are good up to a splice. Light Switch Details The light switch details schematic shows all the wiring between the light switch/relays and the components connected to the output side of the light switch/relays. Power Distribution The Power distribution schematic shows the wiring from the battery and alternator to the: - Starter solenoid - Fuse box - Light switch - Ignition switch - Fuse link The first component after a fuse link is shown. In certain instances, the first component after a fuse box, fuse and light switch is shown. All fuses in the schematic are "Hot At All Times", since battery voltage is the direct source. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 208 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Symbol Identification Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Clear: CLR Gray: GRY Green: GRN Light Blue: LT BLU Light Green: LT GRN Orange: ORN Pink: PNK Red: RED Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 210 White: WHT Yellow: YEL Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 211 Headlamp Switch: Diagnostic Aids Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 212 Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 213 testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 214 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Voltage Check Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 216 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 217 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 218 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 219 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 220 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 221 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 222 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 223 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 224 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 225 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 226 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 227 Headlamp Switch: Electrical Diagrams Light Switch Details Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 228 Light Switch Details Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Light Switch Details Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 230 Light Switch Details Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove steering wheel as outlined under Steering Wheel. 4. Remove screws securing upper and lower steering column covers. Disconnect electrical connectors. 5. Remove windshield wiper/washer switch and/or combination turn signal, headlight dimmer and hazard warning switch by removing retaining screws. 6. Remove lock cylinder housing by removing snap ring and washer, followed by the attaching bolts. 7. Reverse procedure to install. 8. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Crankshaft Position Sensor R.H. side of engine block. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 239 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor PURPOSE Provides information such as firing order and starting timing of each ignition coil. LOCATION R.H. side of engine block. CONSTRUCTION and OPERATION The system uses a magnetic Crankshaft Position (CKP) sensor which protrudes into the block, within approximately .050" of the crankshaft reluctor. The reluctor is a special wheel cast on the crankshaft that has seven machined slots, six of which are equally spaced 60 ° apart. The seventh slot is spaced 10 ° from one of the other slots. As the reluctor rotates with the crankshaft, the slots change the magnetic field of the sensor, causing an induced voltage pulse. By counting the time between pulses, the Ignition Control Module (ICM) can recognize the pulse of the seventh slot (sync pulse). Based on this sync pulse, the module sends the reference signal to the Engine Control Module (ECM) to calculate CKP (used to fire coils in correct sequence) and engine speed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 240 Crankshaft Position Sensor: Service and Repair REMOVE 1. Disconnect battery ground cable. Protection Shield 2. Remove exhaust and transfer protector. 3. Disconnect front propeller shaft joint. Crank Angle Sensor / Crankshaft Position Sensor 4. Disconnect wiring connector at crank angle sensor. 5. Remove mounting nut and remove sensor. REFIT 1. Lubricate O-ring on new sensor and fit to engine block. 2. Fit sensor mounting bolt and tighten to: 87 in lb (10 Nm) 3. Reconnect front propeller shaft joint and tighten to: 46 ft lb (63 Nm) 4. Refit protection shield and tighten bolts to: 27 ft lb (37 Nm) 5. Reconnect battery cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Temperature ........................................................................................................................................ ............................................................... Resistance -18°C (0°F) .......................................................................................................................................... .................................................................. 25K ohms -7°C (20°F) ...................................................... ................................................................................................................................................... 13.5K ohms 4°C (40°F) .................................................................................................................................. .......................................................................... 7.5K ohms 20°C (68°F) ............................................ .............................................................................................................................................................. 3.4K ohms 38°C (100°F) ..................................................................................................................... ................................................................................... 1.8K ohms 70°C (160°F) ................................. .............................................................................................................................................................. ........... 450 ohms 100°C (212°F) ......................................................................................................... ............................................................................................... 185 ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 244 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 245 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature Sensor ECT Sensor PURPOSE Provides engine temperature information to the Engine Control Module (ECM). LOCATION Rear of engine. OPERATION The ECM supplies a 5V signal to the sensor and measures voltage variation. By measuring this variation, the ECM measures coolant temperature. This input is a factor in calculations involving most ECM controlled systems. CONSTRUCTION The coolant temperature sensor is a thermistor (a device whose resistance changes with temperature) mounted in the engine cooling system. Low temperature produces high resistance (100K ohms at -40°C / -40°F) while high temperature produces low resistance (70 ohms at 130°C / 266°F). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 246 Engine Temperature Sensor: Service and Repair ECT Sensor REMOVAL NOTE: Care must be taken when handling Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. - Negative battery cable. - Drain engine coolant system. - Intake manifold assembly. Refer to Fuel Delivery and Air Induction. - Electrical connector - ECT sensor. Remove from rear of engine coolant transfer tube. INSTALLATION - ECT sensor. Apply sealer or equivalent to threads only. - Tighten the ECT sensor to the specified torque Torque 30 N-m (22 lb-ft) - ECT sensor connector - Intake manifold assembly - Negative battery cable. - Refill engine coolant system. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Temperature ........................................................................................................................................ ............................................................... Resistance 20°F (-7°C) .......................................................................................................................................... ............................................................... 13.5K ohms 68°F (20°C) ..................................................... ..................................................................................................................................................... 3.4K ohms 100°F (38°C) .............................................................................................................................. .......................................................................... 1.8K ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 250 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 251 Intake Air Temperature Sensor: Description and Operation MAT Sensor PURPOSE Provides the Engine Control Module (ECM) with intake air temperature. The ECM uses this information to determine air density. LOCATION In the common chamber. OPERATION The ECM supplies a 5V reference signal to the sensor and by measuring the voltage change can determine the manifold air temperature. IAT sensor is also used to control spark timing and delays EGR when intake air is cold. A failure in Intake Air Temperature (IAT) sensor circuit should set a Code 23. CONSTRUCTION The Intake Air Temperature (IAT) Sensor is a thermistor (resistor) whose resistance value varies in relation to the temperature of air entering the engine. Low temperature results in high resistance (100K ohms at -40°C / -40°F); high temperature results in low resistance (70 ohms at 130°C / 266°F). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 252 Intake Air Temperature Sensor: Service and Repair IAT Sensor And MAP Sensor REMOVAL - Negative battery cable. - Wiring connector - Disconnect connector from Intake Air Temperature (Iat) sensor. - IAT sensor INSTALLATION - AT sensor. Apply sealer or equivalent to Threads only. - Tighten the IAT sensor to the specified torque. Torque 30 Nm (22 lb-ft) - Wiring connector Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation KS Circuit PURPOSE Provides a signal to the ECM when engine detonation occurs. LOCATION Knock sensor is mounted in engine block under intake manifold. The solid state module is near the upper R.H. corner of the inner fender. OPERATION When abnormal engine vibrations (spark knock) are present, sensor produces voltage signal which is received by knock sensor (KS) module. As long as KS module sees no voltage from knock sensor, KS sends a signal voltage (8 to 10 volts) to ECM which in turn provides normal spark advance. When the sensor detects a knock is generates voltage. When the KS module receives this voltage it reduce the signal to the ECM to O volts. The ECM then retards the ignition timing. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 259 Manifold Absolute Pressure Sensor: Description and Operation MAP Sensor PURPOSE Measures pressure in the intake manifold. LOCATION On the common chamber. OPERATION The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this to a voltage output. A closed throttle on engine coast down would produce a relatively low MAP output, while a Wide Open Throttle would produce a high output. MAP is the OPPOSITE of what would be measured on a vacuum gage. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under contain conditions, which allows the ECM to automatically adjust for different altitudes. The ECM sends a 5 volts reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A failure in the MAP sensor circuit should set a DTC 33. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 260 Manifold Absolute Pressure Sensor: Service and Repair MAP Sensor REMOVE OR DISCONNECT - Battery negative cable. - Vacuum hose - Electrical connector - Attaching screws - Sensor INSTALL OR CONNECT - Sensor - Attaching screws - Electrical connector - Vacuum hose - Battery negative cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications Oxygen Sensor: Electrical Specifications Normal voltage range .......................................................................................................................... ................................................................... 0.1 - 1.0V Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications > Page 265 Oxygen Sensor: Mechanical Specifications Torque ................................................................................................................................................. ......................................................... 45 Nm (33 ft lb) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 268 Oxygen Sensor: Fuse and Fusible Link Locations Component Location - SOHC In underhood fuse/relay panel. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 269 Oxygen Sensor: Description and Operation HO2S PURPOSE The oxygen (O2) sensor measures the oxygen content of the exhaust. The ECM monitors the sensor to maintain air/fuel mixture of 14.7 to 1. LOCATION In the exhaust pipe, under the vehicle. OPERATION The oxygen sensor monitors atmospheric air versus exhaust gas oxygen content to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). By monitoring the oxygen sensor output voltage, the computer can determine the amount of oxygen in the exhaust gas and adjust the air/fuel mixture accordingly, this is known as "CLOSED LOOP" operation. When the sensor is cold it is like an open circuit and produces no voltage below 600°F (315°C). An open sensor circuit or cold sensor causes "OPEN LOOP" operation. The heated oxygen sensor works in the same manner as the non-heated oxygen sensor. The exception is that B+ is supplied to a heating unit that is part of the sensor itself. This heater receives voltage from the generator charging circuit. The heater helps the ECM control the fuel injection sooner for better fuel emissions. There are no malfunction Codes to detect if the heater part of the sensor is working. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) O2 Sensor REMOVE OR DISCONNECT Caution: ^ The Heated Oxygen Sensor (HO2S) uses a permanently attached pigtail and connector. This pigtail should not be removed from the HO2S. Damage or removal of the pigtail or connector could affect proper operation of the HO2S. ^ Take care when handling the HO2S. The in-line electrical connector and louver end must be kept free of grease, dirt, or other contaminants. Also, avoid using cleaning solvents of any type. Do not drop or roughly handle the HO2S. - Battery negative cable. - HO2S wiring connector. - HO2S NOTE: ^ The HO2S may be difficult to remove when engine temperature is below 45° C (120° F). ^ Excessive force may damage threads in exhaust pipe. INSTALL OR CONNECT - HO2S NOTE: ^ A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite which will burn away, but the glass beads will remain, making the sensor easier to remove. ^ New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason it is to be reinstalled, the threads must have antiseize compound applied before reinstallation. ^ Apply anti-seize compound or equivalent to threads of oxygen sensor if necessary. - Tighten the oxygen sensor to the specified torque. Torque 55 N-m (40 lb-ft) - HO2S wiring connector. - Battery negative cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 272 Oxygen Sensor: Service and Repair Oxygen Sensor Life Indicator Light OXYGEN SENSOR LIFE INDICATOR LIGHT (O2) RESET PROCEDURE At 90,000 mile intervals, the O2 sensor lamp will illuminate. After replacing the sensor, perform the following procedure to reset the lamp. Maintainence Reminder Light Reset - Remove instrument cluster. - Remove masking tape from hole B. - Remove screw from hole A and install into hole B. - Apply new masking tape to hole A. - Install instrument cluster. NOTE: This procedure assumes that the sensor is being replaced for the first time (at 90,000 miles). For subsequent reset procedure (every 90,000 miles), hole positions will be the opposite of this procedure. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Pressure .............................................................................................................................................. ..................................................... Switch Condition Low pressure ....................................................................................................................................... ........................................................................... open High pressure ................................................. ........................................................................................................................................................ continuity Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 276 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 277 Power Steering Pressure Switch: Description and Operation PURPOSE Provides the ECM with power steering load information. LOCATION In the pressure line, near the radiator. OPERATION The Power Steering Pressure Switch tells ECM vehicle is in parking maneuver. ECM will compensate for additional engine load by adjusting idle air control valve and switching OFF A/C compressor when high pressures are detected. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position ................................................................................................................................... ...................................... Signal Voltage To ECM At idle ................................................................................................................................................... ......................................................... less than 1.25V At WOT ............................................................ ................................................................................................................................................ approx. 4.5V Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 281 Throttle Position Sensor: Locations Idle Air Control (IAC) Valve On the throttle chamber. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 282 Throttle Position Sensor: Description and Operation Throttle Position Sensor TPS PURPOSE Informs the ECM with throttle valve position information. LOCATION On the throttle chamber. OPERATION The Throttle Position Sensor (TP) is a potentiometer connected to the throttle shaft on the throttle body assembly. TPS electrical circuit consists of a 5 volt supply line and a ground line, both provided by ECM. By monitoring voltage on this signal line, ECM calculates throttle position. As throttle valve position is changed, output of TPS also changes. At closed throttle position, TPS output is low (approximately .5 volt). At wide open throttle, output is high (approximately 4 volts). A problem in any for TP circuits should set Code 21. Once a Code is set, ECM will use default valve for TP. High idle will result when Code 21 is set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 283 Throttle Position Sensor: Adjustments Throttle Position Sensor (TPS) TPS is an auto zeroing type and cannot be adjusted. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 284 Throttle Position Sensor: Service and Repair TP Sensor REMOVE OR DISCONNECT - Battery negative cable. - Throttle Position (TP) sensor wiring connector - TP sensor fixing screw TP sensor INSTALL OR CONNECT - TP sensor - TP sensor fixing screw - Tighten the fixing screw to the specified Torque. Torque 2 Nm (18 lb-in) - Use a "Scan tool" to check TP sensor output voltage with throttle closed, should be under 0.85 volts. If over 0.85 volts, check for binding throttle shaft, or TP sensor lever. If all OK, replace TP sensor. - TP sensor wiring connector Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Vehicle Speed Sensor - Service Procedure Update Vehicle Speed Sensor: Technical Service Bulletins Vehicle Speed Sensor - Service Procedure Update BULLETIN NUMBER SB93-04-006 ISSUE DATE August 1993 GROUP ELECTRICAL RODEO (UC) VEHICLE SPEED SENSOR SERVICE PROCEDURES (WORKSHOP MANUAL CORRECTION) AFFECTED VEHICLES 1993 Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION Removal, inspection and installation procedures for the vehicle speed sensor are missing from the following Workshop Manual: Manual Page No. 1993 Rodeo (UC) Workshop Manual 8-228 (Publication No. AIMI-SVC-239, part No. 2-20993-072-0) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Vehicle Speed Sensor - Service Procedure Update > Page 289 This Service Bulletin contains vehicle speed sensor service procedures for the referenced Workshop Manual. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Locations Vehicle Speed Sensor (VSS) Instrument Panel In the speedometer head. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Schematics CIRCUIT APPLICATION Circuit schematics break the entire electrical system into individual circuits. Electrical components that work together are shown together. CURRENT FLOW Each drawing is arranged so current flows from positive, at top of page to ground, at bottom. The "hot" labels at the top of a fuse indicate when the ignition switch supplies power to that fuse. CIRCUIT NETWORKING Wires that connect to another circuit are shown with an arrowhead pointing in the direction of current flow. The name of the circuit that shares the wiring is shown for reference. POWER AND GROUND SUPPLY "See Fuse Box Details" indicates there are connections to other circuits that are not shown. All shared circuits are shown on the Fuse Box Details schematic. "See Ground Distribution" indicates there are shared ground circuits which are shown on the ground distribution schematic. CIRCUIT/COMPONENT LOCATION No attempt is made to represent the location or proximity of components. If a wire is actually 4 foot or 4 inches, it will be represented without regard in the schematic. Component/Connector Location and I.D. COMPONENT AND CONNECTOR LOCATION Supplied with the wiring schematic is a component location index. The index lists the correct photograph for the components and connectors listed. The photographs are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. HARNESS ROUTING Harness routing and selected connectors related to the system are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. CONNECTOR I.D. All connectors with more than 2 terminals are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. Fuse Box Details The fuse box details schematic shows all the wiring between a fuse and the components connected to the output side of the fuse. It shows what supplies power to the fuse and when it is energized. Ground Distribution The ground distribution schematics show which components share a common ground point. This information can be very helpful in diagnosing inoperative circuits. If more than one components are not working and they share a common ground, it is likely the ground circuit is faulty. However, if one of the circuits is operative and the other is not, you know the ground and the wire are good up to a splice. Light Switch Details The light switch details schematic shows all the wiring between the light switch/relays and the components connected to the output side of the light switch/relays. Power Distribution The Power distribution schematic shows the wiring from the battery and alternator to the: - Starter solenoid - Fuse box - Light switch - Ignition switch - Fuse link The first component after a fuse link is shown. In certain instances, the first component after a fuse box, fuse and light switch is shown. All fuses in the schematic are "Hot At All Times", since battery voltage is the direct source. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 296 Symbol Identification Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Clear: CLR Gray: GRY Green: GRN Light Blue: LT BLU Light Green: LT GRN Orange: ORN Pink: PNK Red: RED Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 297 White: WHT Yellow: YEL Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 298 Vehicle Speed Sensor: Diagnostic Aids Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 299 Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 300 testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Voltage Check Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 303 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 305 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 309 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 310 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 311 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 312 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 313 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 314 Vehicle Speed Sensor Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 315 Vehicle Speed Sensor: Description and Operation PURPOSE Provides the ECM with vehicle speed information. LOCATION Integral part of the speedometer assembly OPERATION The ECM applies and monitors a 12V signal to the sensor. When the drive wheels are turning, the sensor alternately grounds the circuit, creating a pulsing action. The ECM calculates vehicle speed based on the time between pulses. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 316 Vehicle Speed Sensor: Testing and Inspection VEHICLE SPEED SENSOR (INCORPORATED IN THE SPEEDOMETER) INSPECTION Remove the speedometer from the meter assembly, and measure the resistance value between the terminals. (Fig. 8-365) Replace the speedometer assembly when the result of inspection is found abnormal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 317 Vehicle Speed Sensor: Service and Repair Instrument Panel The vehicle speed sensor is an integral part of the speedometer. If replacement is necessary, replace the speedometer. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position ................................................................................................................................... ...................................... Signal Voltage To ECM At idle ................................................................................................................................................... ......................................................... less than 1.25V At WOT ............................................................ ................................................................................................................................................ approx. 4.5V Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 322 Throttle Position Sensor: Locations Idle Air Control (IAC) Valve On the throttle chamber. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 323 Throttle Position Sensor: Description and Operation Throttle Position Sensor TPS PURPOSE Informs the ECM with throttle valve position information. LOCATION On the throttle chamber. OPERATION The Throttle Position Sensor (TP) is a potentiometer connected to the throttle shaft on the throttle body assembly. TPS electrical circuit consists of a 5 volt supply line and a ground line, both provided by ECM. By monitoring voltage on this signal line, ECM calculates throttle position. As throttle valve position is changed, output of TPS also changes. At closed throttle position, TPS output is low (approximately .5 volt). At wide open throttle, output is high (approximately 4 volts). A problem in any for TP circuits should set Code 21. Once a Code is set, ECM will use default valve for TP. High idle will result when Code 21 is set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 324 Throttle Position Sensor: Adjustments Throttle Position Sensor (TPS) TPS is an auto zeroing type and cannot be adjusted. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 325 Throttle Position Sensor: Service and Repair TP Sensor REMOVE OR DISCONNECT - Battery negative cable. - Throttle Position (TP) sensor wiring connector - TP sensor fixing screw TP sensor INSTALL OR CONNECT - TP sensor - TP sensor fixing screw - Tighten the fixing screw to the specified Torque. Torque 2 Nm (18 lb-in) - Use a "Scan tool" to check TP sensor output voltage with throttle closed, should be under 0.85 volts. If over 0.85 volts, check for binding throttle shaft, or TP sensor lever. If all OK, replace TP sensor. - TP sensor wiring connector Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Crankshaft Position Sensor R.H. side of engine block. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 330 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor PURPOSE Provides information such as firing order and starting timing of each ignition coil. LOCATION R.H. side of engine block. CONSTRUCTION and OPERATION The system uses a magnetic Crankshaft Position (CKP) sensor which protrudes into the block, within approximately .050" of the crankshaft reluctor. The reluctor is a special wheel cast on the crankshaft that has seven machined slots, six of which are equally spaced 60 ° apart. The seventh slot is spaced 10 ° from one of the other slots. As the reluctor rotates with the crankshaft, the slots change the magnetic field of the sensor, causing an induced voltage pulse. By counting the time between pulses, the Ignition Control Module (ICM) can recognize the pulse of the seventh slot (sync pulse). Based on this sync pulse, the module sends the reference signal to the Engine Control Module (ECM) to calculate CKP (used to fire coils in correct sequence) and engine speed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 331 Crankshaft Position Sensor: Service and Repair REMOVE 1. Disconnect battery ground cable. Protection Shield 2. Remove exhaust and transfer protector. 3. Disconnect front propeller shaft joint. Crank Angle Sensor / Crankshaft Position Sensor 4. Disconnect wiring connector at crank angle sensor. 5. Remove mounting nut and remove sensor. REFIT 1. Lubricate O-ring on new sensor and fit to engine block. 2. Fit sensor mounting bolt and tighten to: 87 in lb (10 Nm) 3. Reconnect front propeller shaft joint and tighten to: 46 ft lb (63 Nm) 4. Refit protection shield and tighten bolts to: 27 ft lb (37 Nm) 5. Reconnect battery cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation KS Circuit PURPOSE Provides a signal to the ECM when engine detonation occurs. LOCATION Knock sensor is mounted in engine block under intake manifold. The solid state module is near the upper R.H. corner of the inner fender. OPERATION When abnormal engine vibrations (spark knock) are present, sensor produces voltage signal which is received by knock sensor (KS) module. As long as KS module sees no voltage from knock sensor, KS sends a signal voltage (8 to 10 volts) to ECM which in turn provides normal spark advance. When the sensor detects a knock is generates voltage. When the KS module receives this voltage it reduce the signal to the ECM to O volts. The ECM then retards the ignition timing. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Airbag - On/Off Switch Kit Availability Air Bag Deactivation Switch: Technical Service Bulletins Airbag - On/Off Switch Kit Availability BULLETIN NUMBER: SB98-04-L009 ISSUE DATE: NOVEMBER 1998 GROUP: ELECTRICAL ISUZU DEALER ADVISORY: AVAILABILITY OF AIRBAG ON-OFF SWITCH KITS (SUPERSEDES SB98-04-L003) AFFECTED VEHICLES All Isuzu models equipped with driver and/or passenger airbags. SERVICE INFORMATION Genuine Isuzu Air Bag On-Off Switch Kits are now available from AIPDN. On November 18, 1997, the National Highway Traffic Safety Administration (NHTSA) issued a new regulation, published in the November 21, 1997 Federal Register, allowing motor vehicle owners to have airbag on-off switches installed in their vehicles under certain limited conditions. Under the new regulation, vehicle owners may obtain written authorization from NHTSA to have retrofit driver and/or passenger-side airbag on-off switches installed in their vehicles only if they fall into one or more of the following categories of people at risk: - Those who cannot avoid placing a rear-facing infant seat in the front passenger seat. - Those who have an unusual medical condition that place them at specific risk. - Those drivers who cannot adjust their seating position to keep back approximately 10 inches from the steering wheel. - Those who cannot avoid situations - such as a car pool - that require a child 12 years or under to ride in the front seat. Vehicle owners who are interested in learning about airbag on-off switches may contact NHTSA's toll-free Hotline at 1-800-424-9393 or browse their web site at http://www.nhtsa.dot.gov. NHTSA will provide the vehicle owner with an information brochure Air Bags & On-Off Switches: Information for an Informed Decision and the accompanying form Request for Air Bag On-Off Switch. If after reading the brochure, a vehicle owner decides to seek an authorization letter from NHTSA, he or she must fill out the request form and mail it to NHTSA. If NHTSA approves the request, NHTSA will then send the owner a letter authorizing dealers or other repair outlets to install an on-off switch in his or her vehicle. (Remember that each on-off switch requires a separate authorization letter from NHTSA.). As a final matter, we remind you that the new regulation does not require dealers to install on~off switches under any circumstances; it simply authorizes dealers to take such actions if the customer has a specific authorization letter from NHTSA. Dealers must make their own decisions. PARTS INFORMATION Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Airbag - On/Off Switch Kit Availability > Page 340 Refer to the included reference chart for detailed information concerning Isuzu's Air Bag On-Off Switch Kits, including the component parts, the installation instruction sheet, and the vehicle Owner's Manual insert. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation PURPOSE Informs the ECM when the clutch pedal is depressed. LOCATION On the pedal bracket assembly, on the driversd footwell. OPERATION When the clutch pedal is depressed, a circuit is supplied to ground. The ECM monitors this circuit to provide fuel cut on deceleration Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 345 Clutch Switch: Testing and Inspection 1. Ensure there is continuity between connectors with clutch pedal depressed. 2. Ensure there is no continuity between connectors with clutch pedal released. 3. If continuity is not as specified, replace switch. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position Neutral Safety Switch: All Technical Service Bulletins A/T Mode Switch - No Crank In Neutral Position BULLETIN NUMBER SB93-05-011 ISSUE DATE June 1993 GROUP TRANSMISSION RODEO (UC) AND TROOPER (UX) NO START IN NEUTRAL AFFECTED VEHICLES 1991-93 Rodeo (UC) and 1992-93 Trooper (UX) models equipped with V6 engine and automatic transmission before the following VINS: ^ VIN P4310980 Rodeo 2-wheel drive ^ VIN P4314257 Rodeo 4-wheel drive ^ VIN P7906876 Trooper SERVICE INFORMATION Some affected vehicles may experience a "no start" (no crank) condition when the A/T selector lever is in the neutral position, caused by A/T mode switch failure. Follow the diagnosis procedure in this Service Bulletin to determine if the mode switch requires replacement. If mode switch replacement is necessary, install the mode switch listed in the "Parts Information" section of this Bulletin. SERVICE PROCEDURE NOTE: Refer to the appropriate Electrical Troubleshooting Manual for connector number references. Check mode switch operation as follows: 1. Disconnect the starter solenoid connector (C130 on Trooper; C112 on Rodeo). 2. On 3.2L V6 models, remove the air cleaner assembly. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 354 3. Disconnect the mode switch connector (C113 on Trooper; C139 on '91-92 Rodeo; C135 on '93 Rodeo). See Figure 1. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 355 4. On the mode switch side of the connector, install an ohmmeter between the red wire (violet wire on '91 models) and the yellow wire (Figure 2). 5. a. If the ohmmeter reads continuity with the transmission selector lever in any other position other than "P" (Park) or "N" (Neutral), the mode switch requires adjustment. Adjust mode switch as described in Step 12 of this Service Procedure, then recheck mode switch operation starting from Step 3. After adjusting the mode switch, if the above check still results in continuity with the lever in any other position other than "P" or "N", replace the mode switch (see "Parts Information" section of this Service Bulletin) as described in the appropriate Workshop Manual. Then follow the mode switch adjustment procedure described in Step 12. b. If the ohmmeter reads continuity with the transmission selector lever in "P" or "N", but the engine still does not start with the lever in "N", continue with this diagnosis procedure. 6. Remove the ohmmeter. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 356 7.a. Check mode switch circuit from the starter switch by connecting a voltmeter between the mode switch connector blue/black wire (white/green wire on '91-92 Rodeo) on the harness side, and ground (Figure 3). b. Turn the ignition key to "START" and note voltmeter reading. 8.a. If voltmeter reading is 0 volts, check the circuit from main fuse 1 to the mode switch connector. b. If voltmeter reading is 12 volts, check the ground circuit from the mode switch connector to ground (on Trooper LS models, anti-theft controller ground). Repair circuit as required. 9. Reconnect mode switch connector. 10. Reconnect starter solenoid connector. 11. On 3.2L V6 models, reinstall air cleaner assembly. 12. Mode Switch Adjustment Procedure (Figure 4) a. Place gear selector lever in "N". b. Under the vehicle, remove A/T linkage from the mode switch. c. Remove mode switch cover. d. Loosen the two 6 mm screws in the mode switch. e. Rotate the mode switch until the slot in the mode switch aligns with the selector shaft bushing, and insert a 3/32" (2.4 mm) drill bit or punch into the slot. f. Tighten the screws to 113 in.lbs. Remove the drill bit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 357 g. Reinstall mode switch cover. h. Reinstall gear selector lever. PARTS INFORMATION Part No. Description 8-96017-178-0 Mode Switch (Trooper UX) 8-96017-197-0 Mode Switch (Rodeo) FLAT RATE MANUAL UPDATE INFORMATION Use the revised labor operation. See illustration. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position Neutral Safety Switch: Customer Interest A/T Mode Switch - No Crank In Neutral Position BULLETIN NUMBER SB93-05-011 ISSUE DATE June 1993 GROUP TRANSMISSION RODEO (UC) AND TROOPER (UX) NO START IN NEUTRAL AFFECTED VEHICLES 1991-93 Rodeo (UC) and 1992-93 Trooper (UX) models equipped with V6 engine and automatic transmission before the following VINS: ^ VIN P4310980 Rodeo 2-wheel drive ^ VIN P4314257 Rodeo 4-wheel drive ^ VIN P7906876 Trooper SERVICE INFORMATION Some affected vehicles may experience a "no start" (no crank) condition when the A/T selector lever is in the neutral position, caused by A/T mode switch failure. Follow the diagnosis procedure in this Service Bulletin to determine if the mode switch requires replacement. If mode switch replacement is necessary, install the mode switch listed in the "Parts Information" section of this Bulletin. SERVICE PROCEDURE NOTE: Refer to the appropriate Electrical Troubleshooting Manual for connector number references. Check mode switch operation as follows: 1. Disconnect the starter solenoid connector (C130 on Trooper; C112 on Rodeo). 2. On 3.2L V6 models, remove the air cleaner assembly. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 363 3. Disconnect the mode switch connector (C113 on Trooper; C139 on '91-92 Rodeo; C135 on '93 Rodeo). See Figure 1. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 364 4. On the mode switch side of the connector, install an ohmmeter between the red wire (violet wire on '91 models) and the yellow wire (Figure 2). 5. a. If the ohmmeter reads continuity with the transmission selector lever in any other position other than "P" (Park) or "N" (Neutral), the mode switch requires adjustment. Adjust mode switch as described in Step 12 of this Service Procedure, then recheck mode switch operation starting from Step 3. After adjusting the mode switch, if the above check still results in continuity with the lever in any other position other than "P" or "N", replace the mode switch (see "Parts Information" section of this Service Bulletin) as described in the appropriate Workshop Manual. Then follow the mode switch adjustment procedure described in Step 12. b. If the ohmmeter reads continuity with the transmission selector lever in "P" or "N", but the engine still does not start with the lever in "N", continue with this diagnosis procedure. 6. Remove the ohmmeter. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 365 7.a. Check mode switch circuit from the starter switch by connecting a voltmeter between the mode switch connector blue/black wire (white/green wire on '91-92 Rodeo) on the harness side, and ground (Figure 3). b. Turn the ignition key to "START" and note voltmeter reading. 8.a. If voltmeter reading is 0 volts, check the circuit from main fuse 1 to the mode switch connector. b. If voltmeter reading is 12 volts, check the ground circuit from the mode switch connector to ground (on Trooper LS models, anti-theft controller ground). Repair circuit as required. 9. Reconnect mode switch connector. 10. Reconnect starter solenoid connector. 11. On 3.2L V6 models, reinstall air cleaner assembly. 12. Mode Switch Adjustment Procedure (Figure 4) a. Place gear selector lever in "N". b. Under the vehicle, remove A/T linkage from the mode switch. c. Remove mode switch cover. d. Loosen the two 6 mm screws in the mode switch. e. Rotate the mode switch until the slot in the mode switch aligns with the selector shaft bushing, and insert a 3/32" (2.4 mm) drill bit or punch into the slot. f. Tighten the screws to 113 in.lbs. Remove the drill bit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 366 g. Reinstall mode switch cover. h. Reinstall gear selector lever. PARTS INFORMATION Part No. Description 8-96017-178-0 Mode Switch (Trooper UX) 8-96017-197-0 Mode Switch (Rodeo) FLAT RATE MANUAL UPDATE INFORMATION Use the revised labor operation. See illustration. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 367 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 368 Neutral Safety Switch: Adjustments Perform either of the following adjustment procedures: Procedure 1 - Place selector lever in neutral. - Remove selector lever from the mode switch. Remove the mode switch cover. - Loosen the two 10 mm screws. - Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 in. (2.4 mm) drill bit or punch into the slot. - Tighten the screws to 13 N-m (113 lb-in). - After completing adjustment, snap the mode switch cover into place. - Reinstall the selector lever. Procedure 2 - Place selector lever in neutral. - Disconnect mode switch connector from vehicle harness. - Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. - Loosen two mounting screws. - Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. - Position mode switch in middle of contact range. - Tighten two mounting screws. - Remove multimeter and reconnect harness. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 369 Neutral Safety Switch: Service and Repair REMOVE OR DISCONNECT - Negative (-) battery cable. - Place selector lever in neutral - Mode switch cover - Selector lever Selector lever from the mode switch. - Heat protector from the converter housing. - Air cleaner assembly - Harness connector - Mode switch connector from the engine harness. - Harness clip from the clip bracket of the engine. - Remove two mode switch bolts. - Remove mode switch. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 370 INSTALL OR CONNECT - To install, follow the removal steps in the reverse order, noting the following points; Torque Values Mode switch bolt --- 13 N-m (113 lb-in) Heat protector bolt --- 6 N-m (52 lb-in) Selector lever nut --- 25 N-m (18 lb-ft) ADJUSTMENT Perform either of the following adjustment procedures: Procedure 1 - Place selector lever in neutral. - Remove selector lever from the mode switch. Remove the mode switch cover. - Loosen the two 10 mm screws. - Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 in. (2.4 mm) drill bit or punch into the slot. - Tighten the screws to 13 N-m (113 lb-in). - After completing adjustment, snap the mode switch cover into place. - Reinstall the selector lever. Procedure 2 - Place selector lever in neutral. - Disconnect mode switch connector from vehicle harness. - Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. - Loosen two mounting screws. - Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. - Position mode switch in middle of contact range. - Tighten two mounting screws. - Remove multimeter and reconnect harness. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Pressure .............................................................................................................................................. ..................................................... Switch Condition Low pressure ....................................................................................................................................... ........................................................................... open High pressure ................................................. ........................................................................................................................................................ continuity Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 376 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 377 Power Steering Pressure Switch: Description and Operation PURPOSE Provides the ECM with power steering load information. LOCATION In the pressure line, near the radiator. OPERATION The Power Steering Pressure Switch tells ECM vehicle is in parking maneuver. ECM will compensate for additional engine load by adjusting idle air control valve and switching OFF A/C compressor when high pressures are detected. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Barometric Pressure Sensor, A/T > Component Information > Locations Barometric Pressure Sensor: Locations Left front corner of engine compartment. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Locations Downshift Switch: Locations Beneath dash, near accelerator pedal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Specifications Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Specifications > Page 389 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power Economy Mode Transmission Mode Switch: Description and Operation Power Economy Mode PURPOSE Wen switched ON by the driver, this switch tells the TCM to operate the transmission in power mode. When the switch is OFF, the transmission operates in economy mode. OPERATION When in power mode, the TCM delays upshifts, resulting in more powerful acceleration. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power Economy Mode > Page 392 Transmission Mode Switch: Description and Operation Transmission Mode Switch Park/Neutral Position (PNP) Switch (Auto Only) The Park/Neutral position (PNP) switch indicates to the Engine Control Module (ECM) when the transmission is in park, neutral or drive. This information is used for the exhaust gas recirculation, and the idle air control valve operation. - Vehicle should not be driven with PNP switch disconnected, as idle quality will be affected and a possible false diagnostic trouble code (DTC) 24 (vehicle speed sensor). The PNP switch is part of the neutral/start and backup light switch assembly mounted on the transmission. See CHART C1A for PNP switch check. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 393 Transmission Mode Switch: Service and Repair MODE SWITCH REMOVAL Preparation: ^ Disconnect negative (-) battery cable. ^ Place selector lever in neutral. 1. Mode switch cover 2. Selector lever Disconnect selector lever from the mode switch. 3. Heat protector Remove heat protector from the converter housing. 4. Air cleaner assembly Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 394 5. Harness connector - Disconnect mode switch connector from the engine harness. - Disconnect harness clip from the clip bracket of the engine. 6 Mode switch Remove two mode switch bolts. INSTALLATION - To install, follow the removal steps in the reverse order. MODE SWITCH SETTING PROCEDURE Perform either of the following adjustment procedures: 1. Adjustment without using a multi-meter a. Place selector lever in neutral. b. Remove selector lever from the mode switch. c. Remove the mode switch cover. d. Loosen the two 10 mm screws. e. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 in. (2.4 mm) drill bit or punch into the slot. f. Tighten the screws to 13 N.m (113 lb.in). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever. 2. Adjustment using a multi-meter Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 395 a. Place selector lever in neutral. b. Disconnect mode switch connector from vehicle harness. c. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. d. Loosen two mounting screws. e. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. f. Position mode switch in middle of contact range. g. Tighten two mounting screws. Torque: 13 Nm (113 in.lbf.) h. Remove multimeter and reconnect harness. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications APPROX. RESISTANCE @ -40°F (-40°C) .................................................................................................................................. ..................................................... 672 K ohms @ 32°F (0°C) ............................................................. ................................................................................................................................. 65 K ohms @ 68°F (20°C) ......................................................................................................................................... ................................................... 25 K ohms @ 176°F (80°C) ............................................................. ............................................................................................................................ 2.5 K ohms @ 248°F (120°C) ..................................................................................................................................... ..................................................... 780 ohms @ 302°F (150°C) .......................................................... ................................................................................................................................ 370 ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 402 Transmission Temperature Sensor/Switch: Locations Transmission adapter case. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair Technical Service Bulletin # 9311005 Date: 930801 Body/Interior - Noise Diagnosis & Repair BULLETIN NUMBER SB93-11-005 ISSUE DATE August 1993 GROUP BODY TROOPER MY BODY NOISE DIAGNOSIS AND REPAIR AFFECTED VEHICLES 1992-on Trooper (UX) models. SERVICE INFORMATION This bulletin describes diagnosis and repair of squeak and rattle noises at various areas of affected vehicles. Service Procedure SERVICE PROCEDURE 1. Test drive the vehicle to pinpoint the exact location of the noise. 2. Table 1 lists the most common squeaks/rattles, their causes, and repair charts contained in this Service Bulletin. Refer to the appropriate repair chart(s) for repair instructions. 3. After the repair, test drive the vehicle again to ensure the noise is eliminated. PARTS INFORMATION FLAT RATE MANUAL UPDATE INFORMATION ^ Each repair chart contains the appropriate Flat Rate Manual information for labor time. ^ When submitting warranty claims for repairs described in Charts A thru G using items supplied in bulk, use the appropriate sublet code indicated in the repair chart for reimbursement of material allowance. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 408 Repair Chart A Complaint: Squeak where dash and windshield meet Cause: Instrument panel assembly rubbing against cowl Repair: 1. Remove instrument panel assembly as described in the appropriate Workshop Manual. 2. Prepare four pieces of Noise Reduction Tape, each approximately 4-inches in length. 3. Install tape to top edge of dash cowl upper panel in four places, as shown. 4. Reinstall instrument panel assembly as described in the appropriate Workshop Manual. ^ Use sublet code B3 for $ 1.50. ^ Use the existing Flat Rate Manual labor operation. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 409 Repair Chart B Complaint: Rattle in lower center of dash Cause: Center air outlet grille rubbing against instrument panel cluster Repair: 1. Remove center air outlet grille. 2. Install Noise Reduction Tape along top and bottom front edges of grille, as shown. (Trim tape as necessary to fit properly.) 3. Reinstall center air outlet grille. ^ Use sublet code B2 for $ 0.75. ^ Use the existing Flat Rate Manual labor operation. Repair Chart C Complaint: Rattle from radio area Cause: Radio harness contacting radio chassis Repair: 1. Remove radio from instrument panel. 2. Prepare two 12-inch lengths of Noise Reduction Tape. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 410 3. Wrap tape around radio harness, as shown. 4. Reinstall radio. ^ Use sublet code B5 for $ 2.00. ^ Use the new Flat Rate Manual labor operation. Repair Chart D Complaint: Squeak in front door Cause: 1. Power window switch (driver's door only) 2. Door speaker 3. Armrest rubbing against door trim pad Repair: 1. On driver's door only, if squeak is coming from power window switch: a. Remove power window switch. b. Install Noise Reduction Tape around edge of switch opening in door trim pad. c. Reinstall power window switch. ^ Use sublet code B4 for $ 1.65. ^ Use the existing Flat Rate Manual labor operation. 2. If squeak is coming from door speaker: a. Remove door trim pad. b. Remove speaker assembly. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 411 c. On back of door trim pad, install Noise Reduction Tape around speaker opening and along bottom edge of door, as shown. ^ Use sublet code B5 for $ 2.00. ^ Use the new Flat Rate Manual labor operation(s). 3. If squeak is coming from armrest: a. Remove armrest from door trim pad. b. Remove door trim pad from door. c. On back of door trim pad, install Noise Reduction Tape around edges of armrest opening, as shown. d. Reinstall door trim pad. e. Reinstall armrest to door trim pad. ^ Use sublet code B7 for $ 2.85. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 412 ^ Use the existing Flat Rate Manual labor operation(s). Repair Chart E Complaint: Rattle in adjustable armrest (captain's chair) Cause: Armrest adjustment lever loose Repair: 1. Remove armrest adjustment knob. 2. Wrap a layer of Noise Reduction Tape around adjustment lever. 3. Reinstall armrest adjustment knob. ^ Use sublet code B1 for $ 0.50. ^ Use the existing Flat Rate Manual labor operation. Repair Chart F Complaint: Squeak from front lower right side of vehicle Cause: Power antenna motor rubbing against inner front fender Repair: 1. Remove power antenna motor assembly as described in the appropriate Workshop Manual. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 413 2. Install a 5-inch length of Noise Reduction Tape to the power antenna motor cover, as shown. 3. Reinstall power antenna motor assembly as described in the appropriate Workshop Manual. ^ Use sublet code B1 for $ 0.50. ^ Use the existing Flat Rate Manual labor operation. Repair Chart G Complaint: Rattle in upper right side of engine compartment Cause: Windshield washer reservoir contacting inner front fender Repair: 1. Remove windshield washer reservoir as described in the appropriate Workshop Manual. 2. Install several 4-inch lengths of FOAM TAPE (listed in "Parts Information" section of this Service Bulletin) to the side of the reservoir tank, as shown. 3. Reinstall windshield washer reservoir as described in the appropriate Workshop Manual. ^ Use sublet code B6 for $ 2.25. ^ Use the existing Flat Rate Manual labor operation. Repair Chart H Complaint: Glovebox rattles Cause: Glovebox contact with dash panel Repair: 1. Remove glovebox. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 414 2. Remove and discard rubber stoppers from each side of glovebox. 3. Install a new, longer rubber stopper listed in "Parts Information" section of this Service Bulletin) to both sides of the glovebox. 4. Reinstall glovebox. ^ Use the existing Flat Rate Manual labor operation. Repair Chart I Complaint: Rattle from rear seat Cause: Rear seatback release knob loose Repair: 1. Remove rear seatback release knob. 2. Prepare a 2-inch length of 1/2" diameter heat-shrinkable tubing (see "Parts Information" section of this Service Bulletin). CAUTION Use only a heat gun to shrink tubing. Do not use an open flame. Use a suitable tool to hold the knob when applying heat. 3. Slide the tubing over the seatback release knob shaft. Trim excessive tubing length to within 1/8" beyond end of shaft. Apply heat to tubing until it is completely shrunk over the shaft. 4. Trim tubing to within 1/16" above end of shaft. 5. Reinstall the rear seatback release knob securely. 6. Repeat procedure on release knob on other side of rear seat. ^ Use the new Flat Rate Manual labor operation(s). Repair Chart J Complaint: Squeak in upper left side of instrument panel hood Cause: Hood rubbing against instrument panel Repair: 1. Remove the instrument panel hood assembly as described in the appropriate Workshop Manual. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 415 2. On back of hood, trim approximately 1/16" from corner of hood, as shown, to allow clearance between hood and instrument panel. 3. Reinstall instrument panel hood assembly. ^ Use the existing Flat Rate Manual labor operation. Repair Chart K Complaint: Squeak in A/T lever Cause: A/T lever rubbing against bezel Repair: 1. Remove front console. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 416 2. Loosen four screws securing the A/T bezel. Align bezel to center (left/right and up/down). Resecure bezel. 3. Reinstall front console. ^ Use the existing Flat Rate Manual labor operation. Repair Chart L Complaint: Rattle from front seat Cause: Seat reclining adjuster fixing bolt loose Repair: 1. Remove seat trim. 2. Torque reclining adjuster fixing bolts to 32 ft.lbs. 3. Reinstall seat trim. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Body/Interior - Noise Diagnosis & Repair > Page 417 ^ Use the existing Flat Rate Manual labor operation(s). Repair Chart M Complaint: Rattle from tailgate doors Cause: Tailgate door dovetail bolts contacting striker Repair: 1. Loosen dovetail bolts. 2. Apply chassis grease to underside of bolts heads. 3. Adjust position of bolts to eliminate contact with striker when door is closed. 4. Tighten bolts to 104 in.lbs. 5. Adjust striker as necessary. ^ Use the existing Flat Rate Manual labor operation. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Front Wiper Switch Wiper Switch: Testing and Inspection Front Wiper Switch Fig. 60 Front Wiper Switch Check continuity between switch terminals as shown in Fig. 60. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Front Wiper Switch > Page 423 Wiper Switch: Testing and Inspection Rear Wiper Switch Fig. 62 Rear Wiper Switch Check continuity between switch terminals as shown in Fig. 62. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) Alignment: Technical Service Bulletins Front End Alignment - Inspection (Manual Revision) BULLETIN NUMBER: SB97-06-L002 ISSUE DATE: NOVEMBER 1997 GROUP: SUSPENSION 1992-98 TROOPER (UX), 1991-97 RODEO (UC), 1998 RODEO (UE) FRONT END ALIGNMENT INSPECTION (Workshop Manual Revision) AFFECTED VEHICLES 1992-98 Trooper (UX), 1991-97 Rodeo (UC), 1998 Rodeo (UE) models. SERVICE INFORMATION Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) > Page 429 The inspection procedure contained in Section 3A - Front End Alignment (1992-97 Trooper, 1991-97 Rodeo) and in Section 2A - Power Assisted Steering System (1998 Trooper and 1998 Rodeo) of the listed Workshop Manuals, has been revised. The front end inspection procedure has been revised to include steps to ensure that the vehicle is in an unladen condition (no passengers no loading) and that the spare tire is installed in its normal position. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) > Page 430 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) > Page 431 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) > Page 432 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) > Page 433 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) > Page 434 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End Alignment - Inspection (Manual Revision) > Page 435 This Service Bulletin contains the revised pages to the referenced Workshop Manuals. Revisions to the affected pages are shown. Attach the enclosed pages to the referenced Workshop Manual pages. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment Alignment: Specifications Front Wheel Alignment Short Wheel Base Caster Angle, Degrees: Limits ................................................................................................................................................... .............................................. +1 1/4 to +2 3/4 Desired ....................................................................... ................................................................................................................................................ 2 Camber Angle, Degrees: Limits ................................................................................................................................................... ..................................................... -1/2 to + 1/2 Desired ...................................................................... ................................................................................................................................................. 0 Toe-In, Inch [01] .................................................................................................................................. ................................................................ -.08 to +.08 King Pin Inclination, Degrees .......................... ............................................................................................................................................................ 12 1/2 Knuckle Angle At Full Lock, Degrees; Inside ................................................................................................................................................... ..................................................................... 34 Outside ..................................................................... ................................................................................................................................................ 32 [01] -- Toe-in (+); toe-out (-). Long Wheel Base Caster Angle, Degrees: Limits ................................................................................................................................................... ........................................ +1 5/12 to +2 11/12 Desired ....................................................................... ........................................................................................................................................ +2 1/6 Camber Angle, Degrees: Limits ................................................................................................................................................... ...................................................... -1/2 to +1/2 Desired ...................................................................... ................................................................................................................................................. 0 Toe-In, Inch [01] .................................................................................................................................. ................................................................ -.08 to +.08 King Pin Inclination, Degrees .......................... ............................................................................................................................................................ 12 1/2 Knuckle Angle At Full Lock, Degrees: Inside ................................................................................................................................................... ..................................................................... 34 Outside ..................................................................... ................................................................................................................................................ 32 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment > Page 438 Alignment: Specifications Rear Wheel Alignment This model has a solid rear axle. No specifications exist for Camber or Toe-in. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension Alignment: Service and Repair Front Suspension Caster & Camber Fig. 1 Caster angle adjustment Fig. 2 Camber angle adjustment Caster angle can be adjusted with caster shims installed in position between the chassis frame and the fulcrum pins, Fig. 1. Camber angle can be adjusted with the shims installed in position between the chassis frame and the fulcrum pins, Fig. 2. Toe-In To adjust toe-in angle, loosen locknut on the outer track rod and turn outer track rod with the same degree as right and left, Fig. 3. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension > Page 441 Alignment: Service and Repair Trim Height Trim Height Inspection Procedure Before making any wheel alignment adjustments, inspect the following: 1. Tires for proper inflation pressure. 2. Front wheel bearing for proper adjustment. 3. Ball joints, tie rod ends and relay rods for excessive looseness. 4. Wheels and tires for run out. 5. Vehicle trim height. If not within specifications, trim height must be corrected before adjusting caster. 6. Steering gear for looseness at frame. 7. Shock absorbers for leaks or any noticeable noise. 8. Control arms or stabilizer bar attachment for looseness. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension > Page 442 Alignment: Service and Repair Vehicle Ride Height Vehicle height is adjusted by means of a adjusting bolt on the control arms. Before adjusting height, check tire pressure and ensure vehicle is on level ground. The measurement between the height from the center of the headlights to the ground should be 33-34 inches. There must be no more than 0.393 inch (10 mm) difference between the lefthand and righthand sides of vehicle. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Component Location - SOHC At back of engine. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications ECM controlled, not adjustable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 451 Air/Fuel Mixture: Adjustments The air/fuel mixture is ECM controlled and there is no provision for adjustment. Refer to COMPUTERS AND CONTROL SYSTEMS. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications ECM controlled, not adjustable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 455 Idle Speed: Adjustments The idle speed is Engine Control Module (ECM) controlled and there is no provision for adjustment. Refer to Computers and Control Systems/Testing and Inspection if there is a problem with the idle speed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Testing and Inspection Air Filter Element: Testing and Inspection ^ Remove air filter element from air cleaner box and visually inspect. ^ Replace filter if it appears dirty or oil saturated, or if scheduled maintenance interval has been reached. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Replace all pipes with the same pipe and fittings that were removed. Do not reuse "O" rings. Always replace. - Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair. - Adhere to all Notices and Cautions. NOTE: If available, use system bleed valve (schrader) to relieve pressure. NYLON FUEL PIPE CAUTIONS: In order to reduce the risk of fire and personal injury observe the following items: - Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes - Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115° C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 464 Fuel Pressure Release: Service and Repair 1. Remove fuel filler cap. 2. Remove fuel pump relay from underhood relay center. 3. Start engine and allow to stall. 4. Crank engine for an additional 30 seconds. 5. Remove negative battery cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1 2 3 4 5 6 Firing Order: 1 - 2 - 3 - 4 - 5 - 6 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order: 1 2 3 4 5 6 Firing Order: 1 - 2 - 3 - 4 - 5 - 6 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Ignition Cable: Customer Interest Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 > Spark Plug Tube - Oil Seepage Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Seepage BULLETIN NUMBER: SB97-01-L003 ISSUE DATE: JUNE 1997 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 3.2L V6 SOHC ENGINE SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 3.2L V6 SOHC engine. SERVICE PROCEDURE When servicing affected vehicles experiencing oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface, be sure to refer only to Service Bulletin SB96-01-L005, issued 9/96. The authorized repair for affected vehicles experiencing this condition, is to replace the original spark plug wire set with a new type wire set which features an improved bushing designed to control oil seepage at the spark plug tube-to-cylinder head interface. SB96-01-L005 describes this authorized repair. Do not refer to Service Bulletin SB96-01-L004, issued 4/96, to repair this condition. It is not the authorized repair. SB96-01-L004 is strictly intended to provide detailed service and warranty information when spark plug tube replacement is required. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 > Spark Plug Tube - Oil Seepage Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Seepage BULLETIN NUMBER: SB97-01-L003 ISSUE DATE: JUNE 1997 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 3.2L V6 SOHC ENGINE SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 3.2L V6 SOHC engine. SERVICE PROCEDURE When servicing affected vehicles experiencing oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface, be sure to refer only to Service Bulletin SB96-01-L005, issued 9/96. The authorized repair for affected vehicles experiencing this condition, is to replace the original spark plug wire set with a new type wire set which features an improved bushing designed to control oil seepage at the spark plug tube-to-cylinder head interface. SB96-01-L005 describes this authorized repair. Do not refer to Service Bulletin SB96-01-L004, issued 4/96, to repair this condition. It is not the authorized repair. SB96-01-L004 is strictly intended to provide detailed service and warranty information when spark plug tube replacement is required. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 494 Ignition Cable: Specifications Resistance between terminal ends. Cable # ................................................................................................................................................ .............................................................. x 1000 ohms 1 ........................................................................................................................................................... ................................................................... 6.4 - 14.9 2 ........................................................................................................................................................... ................................................................... 5.7 - 13.1 3 ........................................................................................................................................................... ................................................................... 6.2 - 14.4 4 ........................................................................................................................................................... ................................................................... 5.8 - 13.3 5 ........................................................................................................................................................... ................................................................... 6.4 - 14.9 6 ........................................................................................................................................................... ................................................................... 6.9 - 16.0 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 495 Spark Plug Wires Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 496 Ignition Cable: Description and Operation Ignition Wire PURPOSE Conduct high voltage from the ignition coil to spark plugs. LOCATION Between the coils and spark plugs. CONSTRUCTION The ignition wires have an internal resistance to suppress radio static and to eliminate static that may interfere with sensitive computer components. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 497 Ignition Cable: Testing and Inspection Using an ohm meter, check the resistance between ignition wire terminal ends. Cable # ................................................................................................................................................ .............................................................. x 1000 ohms 1 ........................................................................................................................................................... ................................................................... 6.4 - 14.9 2 ...................................................................... ........................................................................................................................................................ 5.7 - 13.1 3 ................................................................................................................................................ .............................................................................. 6.2 - 14.4 4 ........................................................... .............................................................................................................................................................. ..... 5.8 - 13.3 5 .................................................................................................................................... .......................................................................................... 6.4 - 14.9 6 ............................................... .............................................................................................................................................................. ................. 6.9 - 16.0 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 498 Ignition Cable: Service and Repair Spark Plug Wires Remove wires. Spark Plug Wire Index Be sure to refit to correct terminal. NOTE: Do not cross, twist or pull spark plug wires. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Spark Plug: Customer Interest Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Spark Plug: All Technical Service Bulletins Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement Procedure BULLETIN NUMBER: SB96-01-L004 ISSUE DATE: APRIL 1996 GROUP: ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT (Supersedes SB96-01-L001, to include sublet allowance information) APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug contact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 516 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 64 mm +/- 0.5 mm 2.52 in +/- .02 in Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 517 FLAT RATE MANUAL UPDATE INFORMATION Use the following new labor operation: Use Sublet Code B8 ($8.40) for Loctite 290 reimbursement. Dealers are allowed to claim one 8 milliliter bottle of Loctite 290 per VIN. This sublet code does not require dealer or Zone Service & Parts Manager authorization. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement BULLETIN NUMBER SB95-01-L002 ISSUE DATE AUGUST 1995 GROUP ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug intact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 522 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 523 ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 65 mm +/- 0.5 mm (2.56 in. +/- .02 in). FLAT RATE MANUAL UPDATE INFORMATION Use the new labor operation as shown. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement Procedure BULLETIN NUMBER: SB96-01-L004 ISSUE DATE: APRIL 1996 GROUP: ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT (Supersedes SB96-01-L001, to include sublet allowance information) APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug contact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 529 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 64 mm +/- 0.5 mm 2.52 in +/- .02 in Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 530 FLAT RATE MANUAL UPDATE INFORMATION Use the following new labor operation: Use Sublet Code B8 ($8.40) for Loctite 290 reimbursement. Dealers are allowed to claim one 8 milliliter bottle of Loctite 290 per VIN. This sublet code does not require dealer or Zone Service & Parts Manager authorization. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement BULLETIN NUMBER SB95-01-L002 ISSUE DATE AUGUST 1995 GROUP ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug intact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 535 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 536 ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 65 mm +/- 0.5 mm (2.56 in. +/- .02 in). FLAT RATE MANUAL UPDATE INFORMATION Use the new labor operation as shown. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 537 Spark Plug: Specifications Spark plug gap .................................................................................................................................... .............................. 0.040 - 0.043 in (1.05 - 1.1 mm) Spark plug torque ................................................................................................................................ ...................................................... 14 ft lb (19 Nm) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 538 Spark Plug: Description and Operation Spark Plug Cutaway View PURPOSE Spark plugs allow high-voltage secondary current to arc across a small air gap to ignite the air/fuel mixture in the combustion chamber. Spark Plug Temperature HEAT RANGE The temperature of the spark plug is determined by the length of the insulator and the size of the heatsink area. The longer the insulator, the smaller the heatsink area will be. This causes the spark plug to be hotter. The heat range of the plug is determined by its ability to dissipate heat created during combustion. If too cold a plug is used, the possibility of fouling is increased. A plug that is too hot can cause preignition. Hotter plugs tend to burn cleaner with less deposit build-up. They can be used for stop-start city driving, but not for extended high speed or load conditions as engine damage can occur. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 539 Spark Plug: Testing and Inspection INSPECTION - Check the electrodes and insulators for cracks. Replace if faulty. - Check the electrodes for wear and replace as necessary. - Check the gaskets for damage and replace as necessary. - Check insulation resistance with an ohmmeter. Replace if defective. SPARK PLUG INSULATION RESISTANCE 50 M ohms - Check spark plug gap. Adjust or replace as necessary. SPARK PLUG ELECTRODE GAP 1.05 mm (0.040 in) - If spark plug fouling is excessive, check fuel and electrical systems for possible causes. If those systems are normal, install spark plugs of a higher heat range. - If burning of the electrodes or insulator is considerable, install spark plugs of a lower heat range. SOOTY SPARK PLUGS If the electrodes and insulators are fouled with carbon or oil, the engine will operate efficiently. There are a number of possible causes: Rich fuel mixture. - Retarded ignition timeing. - Excessive engine wear (oil in cylinders). - Incorrect plug gap. BLISTERED OR SCORCHED SPARK PLUGS This condition is caused by excessive temperature at the spark plug. Common causes are: Lean fuel mixture. - Advanced ignition timing. - Incorrect plug gap. - Incorrect plug heat range. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection 1. Start and warm engine to operating temperature. 2. Remove all spark plugs and apply a few drops of engine oil into spark plug holes. 3. Relieve fuel system pressure as outlined under Precautions. 4. Disable ignition system, by removing ignition fuse. 5. Connect a tachometer and crank engine, ensure cranking speed is 300 RPM or higher. 6. Install compression gauge, then crank engine with throttle wide open. 7. Minimum pressure should be 128 psi. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 551 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 552 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 553 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 554 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 560 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 561 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 562 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 563 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 564 Valve Clearance: By Symptom Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 565 None: This is not a warranty matter (see POSSIBLE CAUSE). Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 566 Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 567 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 568 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 569 AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 570 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 571 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 572 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 573 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Page 574 Valve Clearance: Specifications Stem Diameter: Intake ................................................................................................................................................... ...................................... 0.2346-0.2323 inches Exhaust ..................................................................... ................................................................................................................. 0.2343-0.2323 inches Face Angle, Degrees ........................................................................................................................... ............................................................................... 45 Valve Clearance: Intake ................................................................................................................................................... .................................................................. [01] Exhaust ...................................................................... ............................................................................................................................................ [01] [01] -- Hydraulic lifters, no adjustment is necessary. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Page 575 Valve Clearance: Adjustments These engines use hydraulic valve lifters. No valve adjustment is possible. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update Timing Belt: Technical Service Bulletins Timing Belt Installation - Manual Update BULLETIN NUMBER SB92-01-010 ISSUE DATE November 12, 1992 GROUP ENGINE TROOPER (UX) TIMING BELT INSTALLATION (WORKSHOP MANUAL CORRECTION) (This Service Bulletin supersedes SB92-01-006) AFFECTED VEHICLES 1992-93 Trooper (UX) models. SERVICE INFORMATION The timing belt installation procedure is not accurately described in the Workshop Manuals. This Service Bulletin contains the corrected timing belt installation procedure for the referenced Workshop Manual pages. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update > Page 580 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update > Page 581 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update > Page 582 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 583 Timing Belt: Testing and Inspection TIMING BELT INSPECTION Visual check 1. The belt must be replaced if cracks or lacerations are found in the side and rear faces. 2. replacement is necessary when abnormal wear is found in the side face. 3. Replacement is necessary when belt fabric is found to be cracked or disintegrated. 4. Replacement is also necessary when cogs are found to have abnormal wear. 5. Take measurements at 3 - 5 points around the circumference of the belt The belt must be replaced even if a single measurement is beyond the limit. Limit of rubber hardness - 90 (HS) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 584 Timing Belt: Service and Repair The DOHC and SOHC engines both use the same Service and Repair procedure from Isuzu. Make note that the DOHC and SOHC engines both use a single gear for the camshaft but use different alignment marks. Removal Preparation: Battery ground cable. 1. Air cleaner assembly 2. Radiator upper fan shroud - Remove from radiator. 3. Cooling fan assembly - Remove four nuts, then the cooling fan assembly. 4. Power steering pump drive belt 5. Air conditioning compressor drive belt 6. Generator drive belt. 7. Fan pulley assembly. 8. Crankshaft pulley assembly - Using special tool J-8614-O1, hold crankshaft pulley. - Remove center bolt, then the pulley. 9. Oil cooler hose - Remove two cooler hose bracket fixing bolts on the timing cover. 10. Timing belt cover. 11. Pusher. CAUTION: The Pusher prevents air from entering the oil chamber. Its rod must always be facing upward. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 585 12. Timing belt - To prevent the timing belt from getting out of position, put the alignment mark on the cam pulley, the crankshaft pulley and the timing belt before removing the timing belt. CAUTIONS: 1. Do not bend or twist the belt, otherwise its core could be damaged. The belt should not be bent at a radius less than 3Omm. 2. Do not allow oil or other chemical substances to come in contact with the belt. They will shorten the belt life. 3. Do not attempt to pry or stretch the belt with a screwdriver or any other tool during installation. 4. Store timing belt in a cool and dark place. Never expose the belt to direct sunlight or heat. INSTALLATION 12. Timing Belt 1. Align groove of crankshaft timing pulley with mark on oil pump. 2. Align the marks on the camshaft timing pulleys with the corresponding dots on the front plate. NOTE:When timing marks are aligned, no pistons will be on T.D.C. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 586 3. Install timing belt. Align the dotted alignment mark on the timing belt with the mark on the crankshaft gear. NOTE:For correct belt installation, the letters the belt must be able to be read as viewed from the front of the vehicle. It is recommended for easy installation that the belt be secured with double clips after it is installed to each pulley. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 587 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 588 4. Align the alignment mark (white line) on the timing belt with the alignment mark on the RH bank camshaft timing pulley (on the left side as viewed from the front of the vehicle). Secure the belt with a double clip. 5. Turn the crankshaft counterclockwise to remove the belt slack between the crankshaft timing pulley and the RH bank camshaft timing pulley. 6. Install the belt on the water pump pulley. 7. Install the belt on the idle pulley. 8. Align the alignment mark (white line) on the timing belt with the alignment mark on the LH bank camshaft timing pulley. (If the belt is difficult to install, turn the camshaft pulley slightly counterclockwise.) 9. Turn the crankshaft pulley clockwise to give some slack between the crankshaft timing pulley and the RH bank camshaft timing pulley. 10. Install the pusher while pushing the tension pulley to the belt. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 589 11. Pull out the pin from the pusher. Fig. 16 Belt tension pusher installation NOTE:When reusing the pusher, press the pusher to retract the rod (1.4 mm piano wire). 12. Remove double clips from pulleys. Temporarily install the crankshaft pulley. Turn the crankshaft pulley clockwise by two turn and make sure that the rod protrusion is within the standard. Standard: ............................................................................................................................................. ................................ 4 - 6 mm (0.16 - 0.24 in) 13. If out of standard, remove pusher, loosen adjusting bolt, and readjust. Repeat from step 11. Tighten adjusting bolt to the specified torque. Torque: ................................................................................................................................................ ....................................... 42 Nm (31 ft lbs) 11. Pusher - Tighten bolts to the specified torque. Torque: ................................................................................................................................................ ....................................... 19 Nm (14 ft lbs) 9. Timing belt cover - Remove crankshaft pulley that was installed in step 12. - Tighten bolts to the specified torque. Torque: ................................................................................................................................................ ....................................... 17 Nm (12 ft lbs) 9. Oil cooler hose - Tighten oil cooler hose bracket bolts to the specified torque. Torque: ................................................................................................................................................ ....................................... 22 Nm (16 ft lbs) 8. Crankshaft pulley - Using special tool J-8614-01, hold the crankshaft pulley. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Technical Service Bulletins > Page 590 - Tighten center bolt to the specified torque. Torque: ................................................................................................................................................ ................................... 167 Nm (123 ft lbs) 7. Fan pulley assembly - Tighten fixing bolt to the specified torque. Torque: ................................................................................................................................................ ....................................... 22 Nm (16 ft lbs) 6. Generator drive belt. - Engage and adjust 5. Air Conditioning drive belt - Engage and adjust 4. Power steering pump drive belt - Engage and adjust 3. Cooling fan assembly - Tighten nuts to the specified torque. Torque: ................................................................................................................................................ ........................................ 8 Nm (69 in lbs) 2. Radiator upper fan shroud 1. Air cleaner assembly Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 9301005 > May > 93 > Alternator Belt - Squeaking Noise Drive Belt: All Technical Service Bulletins Alternator Belt - Squeaking Noise BULLETIN NUMBER SB93-01-005 ISSUE DATE May 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) BELT NOISE (COLD START) AFFECTED VEHICLES 1992-93 Trooper (UX) and Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION At cold engine start-up, some affected vehicles may experience a squeaking noise coming from the alternator belt. To eliminate the noise, adjust the alternator belt tension to 110 +/- 10 lbs. Alternator belt tension specifications are incorrectly printed in the following Workshop Manuals: Correct alternator belt tension specifications (cold engine) for referenced Workshop Manuals for 3.2L V6 engine are: Initial Tension 180 +/- 10 lbs. Readjustment Tension 110 +/- 10 lbs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 9301005 > May > 93 > Alternator Belt - Squeaking Noise Drive Belt: Customer Interest Alternator Belt - Squeaking Noise BULLETIN NUMBER SB93-01-005 ISSUE DATE May 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) BELT NOISE (COLD START) AFFECTED VEHICLES 1992-93 Trooper (UX) and Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION At cold engine start-up, some affected vehicles may experience a squeaking noise coming from the alternator belt. To eliminate the noise, adjust the alternator belt tension to 110 +/- 10 lbs. Alternator belt tension specifications are incorrectly printed in the following Workshop Manuals: Correct alternator belt tension specifications (cold engine) for referenced Workshop Manuals for 3.2L V6 engine are: Initial Tension 180 +/- 10 lbs. Readjustment Tension 110 +/- 10 lbs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 604 Drive Belt: Specifications CAUTION: ^ It is strongly advised to use a tension gauge to check the tension of this belt. Checking tension by "feel" of belt is not accurate. Tension should be checked using a tension gauge after installation and break-in (about 1,000 km or 620 miles). ^ Tension readjustment of auto tension belt should be made only once when V-type HM' tension has dropped to 40 lb or less and poly V type's to 50 lb or less after the vehicle's total running mileage of 621 miles. ^ As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge. Depress belt with 98N (22 lb) and make sure that slackness is in the range of 8 - 12mm (0.315 0.472 in). Belt tension range to be targeted for cold setting. using a Borrough drive belt tension gauge. DRIVE BELT ADJUSTMENT TENSION ADJUSTMENT Generator & fan pulley drive belt Loosen generator fixing bolt and adjuster lock bolt. Adjust bolt by turning adjust bolt. After installation, tighten lock bolt to the specified tightening torque. Fixing bolt Lock bolt A/C compressor drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Power steering oil pump drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 605 Drive Belt: Testing and Inspection INSPECTION Check drive belts for wear or damage, and replace with new ones as necessary. Check belts for tension, and adjust as necessary. CAUTION: ^ It is strongly advised to use a tension gauge to check the tension of this belt. Checking tension by "feel" of belt is not accurate. Tension should be checked using a tension gauge after installation and break-in (about 1,000 km or 620 miles). ^ Tension readjustment of auto tension belt should be made only once when V-type HM' tension has dropped to 40 lb or less and poly V type's to 50 lb or less after the vehicle's total running mileage of 621 miles. ^ As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge. Depress belt with 98N (22 lb) and make sure that slackness is in the range of 8 - 12mm (0.315 0.472 in). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 606 Drive Belt: Adjustments Belt tension range to be targeted for cold setting. using a Borrough drive belt tension gauge. DRIVE BELT ADJUSTMENT TENSION ADJUSTMENT Generator & fan pulley drive belt Loosen generator fixing bolt and adjuster lock bolt. Adjust bolt by turning adjust bolt. After installation, tighten lock bolt to the specified tightening torque. Fixing bolt Lock bolt A/C compressor drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Power steering oil pump drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Testing and Inspection Air Filter Element: Testing and Inspection ^ Remove air filter element from air cleaner box and visually inspect. ^ Replace filter if it appears dirty or oil saturated, or if scheduled maintenance interval has been reached. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Replace all pipes with the same pipe and fittings that were removed. Do not reuse "O" rings. Always replace. - Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair. - Adhere to all Notices and Cautions. NOTE: If available, use system bleed valve (schrader) to relieve pressure. NYLON FUEL PIPE CAUTIONS: In order to reduce the risk of fire and personal injury observe the following items: - Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes - Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115° C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 616 Fuel Pressure Release: Service and Repair 1. Remove fuel filler cap. 2. Remove fuel pump relay from underhood relay center. 3. Start engine and allow to stall. 4. Crank engine for an additional 30 seconds. 5. Remove negative battery cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair The OEM service manual does not provide service and repair information for this component. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Fluid Type DOT 3 or 4 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Type ..................................................................................................................................................... .................................... DOT-3 hydraulic brake fluid Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Acceptable for Use Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Acceptable for Use BULLETIN NUMBER SB96-14-L002 ISSUE DATE JANUARY 1996 GROUP MISCELLANEOUS PROPYLENE GLYCOL - BASED ENGINE COOLANT (Supersedes SB94-14-005) AFFECTED VEHICLES All Isuzu passenger, sport utility, and light truck models. SERVICE INFORMATION Isuzu has determined that propylene glycol-based engine coolants, such as Safe Brands' Sierra engine coolant, will perform adequately under most vehicle operating conditions. As a result, propylene glycol-based engine coolants may be used in Isuzu vehicles. A few important points to remember regarding propylene glycol-based engine coolants: ^ Freeze/boil point levels for propylene glycol are different than for ethylene glycol. ^ To accurately determine the freeze/boil protection level, it is imperative that the coolants not be mixed. ^ Prior to adding propylene glycol engine coolant to the cooling system, all ethylene glycol coolant must be removed. ^ When changing the coolant to propylene glycol, be certain to thoroughly flush the heater core and block as well as the radiator. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Acceptable for Use > Page 632 Coolant: Technical Service Bulletins Coolant - Propylene Glycol Not Approved by Isuzu BULLETIN NUMBER SB94-14-005 ISSUE DATE DECEMBER 1994 GROUP MISCELLANEOUS PROPYLENE GLYCOL-BASED ENGINE COOLANT WARNING AFFECTED VEHICLES All Isuzu passenger and light duty models. SERVICE INFORMATION Some new propylene glycol-based engine coolants, such as Safe Brands' Sierra engine coolant, have recently been marketed in the automotive service industry as "environmentally safe" alternatives to conventional ethylene glycol-based engine coolants. Propylene glycol-based engine coolants are not approved by Isuzu for use in Isuzu vehicles. Propylene glycol-based engine coolants do not meet Isuzu engine coolant specifications. Use of propylene glycol-based engine coolants in Isuzu vehicles can cause the following: ^ Reduced heater and defroster performance. ^ Decreased boil protection and freeze protection. ^ Decreased cylinder head heat transfer. ^ Corrosion damage to cooling system metals (if mixed with ethylene glycol-based engine coolant). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity, Quarts: Manual Transmission .......................................................................................................................... .................................................................... 9.3 Automatic Transmission ........................................... ............................................................................................................................................... 9.0 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 635 Coolant: Fluid Type Specifications Type .................. Mixture of water and good quality ethylene glycol base type antifreeze. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Dexron-IIE Fluid - Recommended Usage Fluid - A/T: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage BULLETIN NUMBER: SB93-14-003 ISSUE DATE April 8, 1993 GROUP MISCELLANEOUS USE OF DEXRON(R)-IIE FLUID AFFECTED VEHICLES All ISUZU models using DEXRON(R)-II fluid in the transmission or powersteering system. SERVICE INFORMATION Effective 12/31/92, DEXRON(R)-II was replaced by DEXRON(R)-IIE fluid, which is an upgraded version of the same product. DEXRON(R)-IIE meets all of the DEXRON(R)-II requirements and should be used for all previous DEXRON(R)-II applications. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Oil Capacity 9.1 qt (US) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 642 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid ............................................................................................................. ....................................................... Dexron II/IIE/III Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 643 Fluid - A/T: Testing and Inspection CHECKING TRANSMISSION FLUID LEVEL 1. Park the vehicle on level ground. 2. Apply the parking brake. 3. Place the automatic transmission in "Park" and start the engine. Allow the engine to idle for two minutes. 4. With the brakes applied, move the shifter lever through all the gear ranges, ending in "Park". 5. Remove the dipstick, ,carefully touch the dipstick with your finger to determine the temperature of the fluid. - If the fluid is cool or warm (approximately room temperature) or slightly higher (but not too hot to touch), the fluid level should be within the "Cold" range. - If the fluid is hot, the fluid level should be within the "Hot" range. - If the vehicle has just been driven for a long period of time at highway speeds or in city traffic in hot weather, wait 30 minutes for the fluid to cool down before checking fluid level. 6. If fluid level is low, add enough DEXRON (R)-II Automatic Transmission Fluid to bring transmission to its proper fluid level through the transmission oil filler tube. NOTE: Overfilling or underfilling could result in damage to the transmission. - If fluid level is low, inspect the area around the oil pan for leakage. - If the fluid smells burnt or is black, replace it. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 644 Fluid - A/T: Service and Repair CHANGING TRANSMISSION FLUID There is no need to change the transmission fluid unless the transmission is used under one or more of the following heavy duty conditions. A: Repeated short trips B: Driving on rough roads C: Driving on dusty roads D: Towing a trailer If the vehicle is used under these conditions, change the fluid every 20,000 miles (32,000 km.) There is no drain plug in the oil pan. Oil should be extracted with suitable suction device through the filler tube. Alternately the fluid can be drained by carefully removing the oil pan. Place a large drain pan under the oil pan, remove 13 bolts on the right, left and front sides of the oil pan and loosen 3 bolts on the rear side. Drain the fluid carefully. Hold the pan horizontally, remove the remaining 3 bolts and remove pan and gasket. Clean the oil pan and reinstall it with a new gasket. It is also recommended to replace the fixing bolts. Tighten 16 fixing bolts to 11 Nm (8 lb. ft.) torque. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Dexron-IIE Fluid - Recommended Usage Fluid - M/T: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage BULLETIN NUMBER: SB93-14-003 ISSUE DATE April 8, 1993 GROUP MISCELLANEOUS USE OF DEXRON(R)-IIE FLUID AFFECTED VEHICLES All ISUZU models using DEXRON(R)-II fluid in the transmission or powersteering system. SERVICE INFORMATION Effective 12/31/92, DEXRON(R)-II was replaced by DEXRON(R)-IIE fluid, which is an upgraded version of the same product. DEXRON(R)-IIE meets all of the DEXRON(R)-II requirements and should be used for all previous DEXRON(R)-II applications. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications 5 Speed 3.1 pt (US) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 651 Fluid - M/T: Fluid Type Specifications OIL VISCOSITY CHART FOR MANUAL TRANSMISSION AND TRANSFER CASE Fluid Type ............................................................................................................................................ ................................................................ Engine Oil Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Capacity ............................................................................................................................................... ........................................................ 1.5 liter (1.6 qt) Rear Differential Capacity ............................................................................................................................................... ........................................................ 1.8 liter (1.9 qt) Differential 1990-94 W/Saginaw rear axle .......................................................................................................................... 80W-90 GL-5(Gear Oil, API Service GL-5) All Others ........................................................................................................ .............................................................................................................. GL-5 Above 50°F (10°C) .............................................................................................................................. ............................................................................ 140 0° to 90°F (-18° to 32°C) ................................. .............................................................................................................................................................. .... 90 Below 50°F (10°C) ..................................................................................................................... .............................................................................. 80W-90 CAPACITY, Refill: Front ...................................................................................................................... ................................................................................. 1.5 liters 3.2 pints Rear: 2.3L ...................................................................................................................................................... ............................................ 1.5 liters 3.2 pints 2.6L, 2.8L, 3.1L, 3.2L ................................................ ...................................................................................................................... 1.8 liters 3.8 pints All with Saginaw axle ................................................................................................................................ ....................................... 1.9 liters 4.0 pints Saginaw axle has removable rear cover without fill plug. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 656 Fluid - Differential: Fluid Type Specifications OIL VISCOSITY CHART FOR FRONT AXLE AND REAR AXLE Standard differential ................................. GL-5 gear lubricant Limited Slip Differential ............................. GL-5 Limited slip differential gear lubricant Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Fluid Capacity ...................................................................................................................................... ..................................................... 1.45 Liter (1.5 qt) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 661 Fluid - Transfer Case: Fluid Type Specifications Transfer Case ...................................................................................................................................... ....................................... SAE 5W-30SF (Engine Oil) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting Engine Oil: All Technical Service Bulletins Engine - Oil Usage Testing and Reporting 2007 Service Bulletins TSB SB07-01-S001 ISSUE DATE: JANUARY 2007 Engine Oil Usage Testing and Reporting (This Bulletin Supersedes SB04-01-S004) Affected Vehicles All Light Duty Isuzu Vehicles Service Information This bulletin has been revised to include new mileage information for Ascender, i-280, i-290, i-350, and i-370 vehicles and to update Model Years. Before performing any warranty repairs, based on a customer's complaint of excessive engine oil consumption, the attached Engine Oil Usage Test/Report must be completed in full. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 670 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 671 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 672 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 673 The updated Engine Oil Usage Test / Report is divided into two parts, PROCEDURE # 1 and PROCEDURE # 2. Procedure # 1, the inspection and testing portion of the Engine Oil Usage Test / Report, are eligible for warranty submission. Procedure # 1 warranty claim may only be submitted ONE time per vehicle. Review Procedure # 1 Results and perform the appropriate action. Complete all steps in Procedure #1 before continuing on to Procedure # 2 (if required). Procedure # 2, the validation portion, is NOT reimbursable under warranty. Complete all steps in Procedure # 2. Review Procedure # 2 Results and perform the appropriate action. The Technician, Service Manager and Customer are to acknowledge the findings by signing and dating the bottom of the Engine Oil Usage Test / Report. Attach a copy of the completed report to the back of the Repair Order (R/O) hard copy and provide a copy to the customer. NOTE: 1. Normal authorization procedures must be followed for such repairs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 674 2. Information released on paper and electronic format prior to bulletin release cannot be updated. For the most current and up to date information refer to website. All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the combustion process. As a result, varying rates of oil consumption are accepted as normal in all engines. Oil Consumption The accepted rate of oil consumption for engines used in Ascender, i-280, i-290, i-350, and i-370 vehicles is 1 quart (0.946 liter) in 2,000 miles (3200 km). The accepted rate of oil consumption for engines used in Trooper (UX), Axiom (UP), VehiCROSS (VX), Rodeo (UE), and Rodeo Sport/Amigo (UA) vehicles is 1 quart (0.473 liter) in 1,000 mi (1600 km). IMPORTANT: Always refer to the Isuzu Service Policies and Procedures Manual for specific details on warranty coverage and policies. This rate only applies to personal use vehicles, under warranty, that are driven in a non-aggressive manner and maintained in accordance with the appropriate maintenance schedule, with less than 36,000 miles (58,000 km), driven at legal speeds in an unloaded (for trucks) condition. IMPORTANT: This rate does not apply to vehicles that are driven in an aggressive manner, at high RPM, high speeds, or in a loaded condition (for trucks). Oil consumption for vehicles driven under these conditions will be more. Many factors can affect a customer's concern with oil consumption. Driving habits and vehicle maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether the vehicle in question has abnormal engine oil consumption. Gasket and External Leaks Inspect the oil pan and engine covers for leakage due to overtightened, damaged, or out of place gaskets. Inspect oil lines and fittings for signs of leakage. Improper Reading of the Oil Level Indicator (Dipstick) Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the engine/vehicle that is being checked. IMPORTANT: Refer to the Owner Manual for checking and adding engine oil. Not Waiting Long Enough After Running Engine to Check Oil Level Some engines require more time than others for the oil to drain back into the crankcase. To assure a sufficient amount of oil has drained back to the crankcase, and an accurate reading can be obtained, the vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off, before taking an oil level reading. In order to ensure accurate results, the temperature of the oil should be close to the same temperature as the last time the oil level was checked. Improper Oil Fill After an Oil Change Following an oil change, verify that the proper amount and type of oil was put in the engine and that the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's Manual or Service Manual for information on recommended oil quantity, viscosity, and quality. Aggressive Driving, High Speed or High RPM Driving Aggressive driving and/or continuous driving at high speeds/high RPM will increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected. Towing or Heavy Usage Towing a trailer will increase oil consumption and may cause oil consumption to fall below the normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use application. Large frontal area trailers will further increase the work required from the engine, especially at highway speeds, and thus increases the rate of oil consumption. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 675 Crankcase Ventilation System Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages, restrictions, or damage to the PCV system can result in increased oil use. Oil Dilution (Fuel and Water) On vehicles that are usually driven short distances, less than 5 miles (8 km), especially in colder weather, unburned fuel and condensation generated from cold engine operation may not get hot enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the customer the impression of excessive oil consumption. Engine Temperature If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort, piston rings may stick, and excessive wear may result. Verify that all cooling system components are in proper working order. Engine Wear Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn, damaged or improperly installed valve guides, seals and piston rings will all cause an increase in oil consumption. Disclaimer Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 680 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 681 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 682 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 683 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 689 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 690 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 691 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 692 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting Engine Oil: All Technical Service Bulletins Engine - Oil Usage Testing and Reporting 2007 Service Bulletins TSB SB07-01-S001 ISSUE DATE: JANUARY 2007 Engine Oil Usage Testing and Reporting (This Bulletin Supersedes SB04-01-S004) Affected Vehicles All Light Duty Isuzu Vehicles Service Information This bulletin has been revised to include new mileage information for Ascender, i-280, i-290, i-350, and i-370 vehicles and to update Model Years. Before performing any warranty repairs, based on a customer's complaint of excessive engine oil consumption, the attached Engine Oil Usage Test/Report must be completed in full. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 698 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 699 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 700 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 701 The updated Engine Oil Usage Test / Report is divided into two parts, PROCEDURE # 1 and PROCEDURE # 2. Procedure # 1, the inspection and testing portion of the Engine Oil Usage Test / Report, are eligible for warranty submission. Procedure # 1 warranty claim may only be submitted ONE time per vehicle. Review Procedure # 1 Results and perform the appropriate action. Complete all steps in Procedure #1 before continuing on to Procedure # 2 (if required). Procedure # 2, the validation portion, is NOT reimbursable under warranty. Complete all steps in Procedure # 2. Review Procedure # 2 Results and perform the appropriate action. The Technician, Service Manager and Customer are to acknowledge the findings by signing and dating the bottom of the Engine Oil Usage Test / Report. Attach a copy of the completed report to the back of the Repair Order (R/O) hard copy and provide a copy to the customer. NOTE: 1. Normal authorization procedures must be followed for such repairs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 702 2. Information released on paper and electronic format prior to bulletin release cannot be updated. For the most current and up to date information refer to website. All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the combustion process. As a result, varying rates of oil consumption are accepted as normal in all engines. Oil Consumption The accepted rate of oil consumption for engines used in Ascender, i-280, i-290, i-350, and i-370 vehicles is 1 quart (0.946 liter) in 2,000 miles (3200 km). The accepted rate of oil consumption for engines used in Trooper (UX), Axiom (UP), VehiCROSS (VX), Rodeo (UE), and Rodeo Sport/Amigo (UA) vehicles is 1 quart (0.473 liter) in 1,000 mi (1600 km). IMPORTANT: Always refer to the Isuzu Service Policies and Procedures Manual for specific details on warranty coverage and policies. This rate only applies to personal use vehicles, under warranty, that are driven in a non-aggressive manner and maintained in accordance with the appropriate maintenance schedule, with less than 36,000 miles (58,000 km), driven at legal speeds in an unloaded (for trucks) condition. IMPORTANT: This rate does not apply to vehicles that are driven in an aggressive manner, at high RPM, high speeds, or in a loaded condition (for trucks). Oil consumption for vehicles driven under these conditions will be more. Many factors can affect a customer's concern with oil consumption. Driving habits and vehicle maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether the vehicle in question has abnormal engine oil consumption. Gasket and External Leaks Inspect the oil pan and engine covers for leakage due to overtightened, damaged, or out of place gaskets. Inspect oil lines and fittings for signs of leakage. Improper Reading of the Oil Level Indicator (Dipstick) Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the engine/vehicle that is being checked. IMPORTANT: Refer to the Owner Manual for checking and adding engine oil. Not Waiting Long Enough After Running Engine to Check Oil Level Some engines require more time than others for the oil to drain back into the crankcase. To assure a sufficient amount of oil has drained back to the crankcase, and an accurate reading can be obtained, the vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off, before taking an oil level reading. In order to ensure accurate results, the temperature of the oil should be close to the same temperature as the last time the oil level was checked. Improper Oil Fill After an Oil Change Following an oil change, verify that the proper amount and type of oil was put in the engine and that the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's Manual or Service Manual for information on recommended oil quantity, viscosity, and quality. Aggressive Driving, High Speed or High RPM Driving Aggressive driving and/or continuous driving at high speeds/high RPM will increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected. Towing or Heavy Usage Towing a trailer will increase oil consumption and may cause oil consumption to fall below the normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use application. Large frontal area trailers will further increase the work required from the engine, especially at highway speeds, and thus increases the rate of oil consumption. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 703 Crankcase Ventilation System Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages, restrictions, or damage to the PCV system can result in increased oil use. Oil Dilution (Fuel and Water) On vehicles that are usually driven short distances, less than 5 miles (8 km), especially in colder weather, unburned fuel and condensation generated from cold engine operation may not get hot enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the customer the impression of excessive oil consumption. Engine Temperature If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort, piston rings may stick, and excessive wear may result. Verify that all cooling system components are in proper working order. Engine Wear Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn, damaged or improperly installed valve guides, seals and piston rings will all cause an increase in oil consumption. Disclaimer Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Refill, quarts including filter ................................................................................................ ........................................................................... 5.7 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 706 Engine Oil: Fluid Type Specifications Oil Viscosity Engine Oil Type .......................... SG/CC, SG/CD, SG, SF/CC, SF/CD SF, SE/CC, SE/CD or SE Engine Oil Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Dexron-IIE Fluid - Recommended Usage Power Steering Fluid: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage BULLETIN NUMBER: SB93-14-003 ISSUE DATE April 8, 1993 GROUP MISCELLANEOUS USE OF DEXRON(R)-IIE FLUID AFFECTED VEHICLES All ISUZU models using DEXRON(R)-II fluid in the transmission or powersteering system. SERVICE INFORMATION Effective 12/31/92, DEXRON(R)-II was replaced by DEXRON(R)-IIE fluid, which is an upgraded version of the same product. DEXRON(R)-IIE meets all of the DEXRON(R)-II requirements and should be used for all previous DEXRON(R)-II applications. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 711 Power Steering Fluid: Specifications GENERAL SPECIFICATIONS Fluid Type ............................................................................................................................................ ................................................... Dexron-II E ATF Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - SAE J2788 Refrigerant Recovery Standard Refrigerant: Technical Service Bulletins A/C - SAE J2788 Refrigerant Recovery Standard Information: IB07-12-S004 Issue Date: AUGUST 2007 New SAE J2788 Refrigerant Recovery Standard Affected Vehicles All Isuzu Light Duty Vehicles Service Information New SAE J2788 Refrigerant Recovery Standard A new SAE standard approved for R134a Refrigerant Recovery Recharging Equipment (SAE J2788) replaces SAE J2210 as the standard covering all mobile refrigerant recovery recharge equipment. SAE J2788 contains several mandates that enhance vehicle A/C service for two key reasons. The standard reduces the amount of refrigerant that can be lost to the atmosphere due to growing concerns over global warming and greenhouse gas emissions. The standard also more tightly controls the equipment accuracy for recharging due to OEM vehicle system refrigerant capacities becoming smaller, which requires a more accurate charge for peak operating performance. SAE J2788 will supersede J2210 in December 2007. At this time manufacturers will no longer be able to produce J2210 equipment. IMPORTANT: This new standard does not affect equipment already produced before December 2007. You DO NOT have to replace the equipment that you are currently using. The Environmental Protection Agency (EPA) is currently in the process of rewriting the Federal Registry, which will likely prohibit sale of SAE J2210 equipment at the end of March 2008. ^ The EPA does not currently have a plan to ban the use of J2210 equipment. ^ Current J2210 equipment can continue to be used by service locations for the useful life of the equipment. ^ Purchase of new compliant equipment is not a requirement of SAE J2788 or the EPA. New machinery built after December 2007 will meet or exceed the new specifications. The SPX Robinair model 34788 was the first product certified to J2788 and has been in full production and in service since December 2006. It meets all requirements outlined above and includes numerous user friendly features beyond the SAE standard. Please contact Isuzu Dealer Equipment Program Customer Service for additional product information. Disclaimer Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - SAE J2788 Refrigerant Recovery Standard > Page 716 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Precautions 2006 Service Bulletins Information IB06-12-S001 Contaminated R134A Refrigerant Found On Market For Automotive Air-Conditioning Systems ISSUE DATE: AUGUST 2006 Affected Vehicles All Isuzu Vehicles using R134a Refrigerant Service Information Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. NOTE: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use Isuzu sourced refrigerants for all A/C repair work. These refrigerants meet Isuzu Motors America, Inc.'s own internal standards for quality and purity. Parts Information Disclaimer Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Type R-12 System Capacity 1.87 lb (US) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 719 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. .......................................................................... R-12 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 720 Refrigerant: Service Precautions Service Procedures The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFC's are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Alternative Refrigerants The introduction of alternative refrigerants, primarily the hydrofluorocarbon (HFC) 134a, aims at preventing further ozone layer depletion. Because 134a is chlorine free, it is deemed ozone safe. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 http://www.macsw.org/ Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Oil Viscosity D-220WX Total System Capacity 5.0 oz (US) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 725 Refrigerant Oil: Fluid Type Specifications Oil Type/Viscosity R-4 Compressor 525 DKS-13 Compressor FREOL DS-83P or equivalent. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair BLEEDING BRAKE HYDRAULIC SYSTEM A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are disconnected at any fitting located between the master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4-Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 40A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine. NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. In replenishing brake fluid, take care that air bubbles do not enter the brake fluid. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures described below. Bleeding The Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 7 through 9 until the brake fluid comes out of the delivery port during step 7. NOTE: Do not allow the fluid level in the reservoir to go below the half-way mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly. 16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces. 17. Bleed the air from the front wheel brake pipe connection (2) by repeating steps 7 through 16. Bleeding The Caliper 18. Bleed the air from each wheel in the order listed below: ^ Right rear caliper ^ Left rear caliper ^ Right front caliper ^ Left front caliper Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 729 Conduct air bleeding from the wheels in the above order. If no brake fluid comes out, it suggests that air is mixed in the master cylinder. In this case, bleed air from the master cylinder in accordance with steps 7 through 17, and then bleed air from the caliper. 19. Place the proper size box end wrench over the bleeder screw. 20. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a transparent container containing brake fluid . 21. Pump the brake pedal slowly three (3) times (once/sec), then hold it depressed. 22. Loosen the bleeder screw until fluid flows through the tube. 23. Retighten the bleeder screw. 24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level. 27. Depress the brake pedal to check if you feel "sponginess" after the air has been removed from all wheel cylinders and calipers. If the pedal feels "spongy", the entire bleeding procedure must be repeated. 28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the "MAX" level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping Air Bag(s) Arming and Disarming: Service Precautions Air Bag Assembly Handling/Shipping/Scrapping Undeployed Air Bag Air Bag Assembly Handling/Shipping/Scrapping NOTE: Refer to the latest service bulletins for proper SRS inflator module shipping procedures. CAUTION: When you are performing service on or near the SRS components or the SRS wiring, you must disable the SRS. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SRS repairs. 1. Air bag assembly should not be subjected to temperatures above 93°C (200°F). 2. Air bag assembly, and Sensing and Diagnostic Module (SDM) should not be used if they have been dropped from a height of 100 cm (3.28 feet). 3. When a SDM is replaced, it must be oriented with the arrow on the sensor pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code. 5. The "SRS Diagnostic System Check" must be the starting point of any SRS diagnostics. The "SRS Diagnostic System Check" will verify proper "AIR BAG" warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement. Live (Undeployed) Air Bag Assembly Special care is necessary when handling and storing a live (undeployed) air bag assembly. The rapid gas generation produced during deployment of the air bag could cause the air bag assembly, or an object in front of the air bag assembly, to be thrown through the air in the unlikely event of an accidental deployment. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 734 WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG OPENING IS POINTED AWAY FROM YOU. IN CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. NEVER CARRY THE AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF THE MODULE. Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies Service personnel should refer to the latest Service Bulletins for proper Supplemental Restraint System (SRS) air bag assembly shipping procedures. Air Bag Assembly Scrapping Procedure During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) air bag assembly. This information covers proper procedures for disposing of a live air bag assembly. Before a live air bag assembly can be disposed of, it must be deployed. Alive air bag assembly must not be disposed of through normal refuse channels. WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. AN UNDEPLOYED AIR BAG ASSEMBLY MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS.THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL.DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE, AND / OR LOCAL LAW. In situations which require deployment of a live air bag assembly module, deployment may be accomplished inside or outside the vehicle. The method employed depends upon the final disposition of the particular vehicle, as noted in "Deployment Outside Vehicle" and "Deployment Inside Vehicle" in this section. Deployed Air Bag Deployed Air Bag Assembly WARNING: You should wear gloves and glasses. After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by-products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1% (each) of the total particulate." Driver Airbag Assembly After the air bag assembly has been deployed, the surface of the air bag may contain solid particulate. This solid particulate consists primarily of by products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in amounts of about 1% (each) of the total particulate. Passenger air bag assembly Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 735 After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 736 Air Bag(s) Arming and Disarming: Service Precautions Electrical Test Equipment When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Inserting the probe into the terminal side of the connector, and tampering the connector could cause malfunction of the SRS system or an error in inspection. Use a probe with the correct tip. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using tools which are not specified standard design could cause an error in inspection due to poor metal-to-metal contact. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 737 Air Bag(s) Arming and Disarming: Service Precautions Fasteners 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 fastener 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 specifications. Following these instructions can help you avoid damage to parts and systems. CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. fasteners that are not reused, and those requiring thread locking compound will be called out. the correct torque value must be used when installing fasteners that require it. if the above conditions are not followed, parts or system damage could result. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 738 Air Bag(s) Arming and Disarming: Service Precautions Wiring Never attempt to modify, splice or repair SRS wiring. NOTE: SRS wiring can be identified by special yellow outer protective covering. Be sure to install the harness wires so that they are not pinched or interfering with other parts. Make sure all SRS ground locations are clean and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 739 Air Bag(s) Arming and Disarming: Service and Repair PRECAUTIONS 1. To avoid accidental deployment and possible personal injury, always disarm the system prior to performing service procedure. Wait at least ten minutes after disconnecting the cable prior to performing any service. The SIR System is designed to retain enough voltage to deploy the air bag for a short time even after the battery ground cable has been disconnected. Performing service before a minimum of ten minutes has elapsed may cause air bag deployment and possible injury. 2. To avoid deployment when troubleshooting the SIR system, do not use electrical test equipment, such as battery powered or A/C powered voltmeter, ohmmeter or any type of electrical equipment other than specified. Do not use a non-powered probe type tester. 3. The passenger compartment sensors must always be installed with arrow mark facing the front of the vehicle for proper operation. 4. Check sensors for cracks, deformities or rust before installation and replace as required. 5. When handling or storing an air bag module, always position with the pad side facing upward. 6. Keep air bag assembly free of oil, grease, detergents and water. 7. Do not expose air bag assembly to temperatures that exceed 212° F. 8. Do not use SIR system components from another vehicle. Always install new replacement components on vehicle. 9. Inspect all components prior to installation. Do not install any components that appear to have been improperly handled or stored or that show any signs of damage. 10. When performing service procedure, do not expose sensors/wiring or other SIR system components to heat guns, welding or spray guns. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Specifications Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Engine Compartment > Page 746 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Schematics CIRCUIT APPLICATION Circuit schematics break the entire electrical system into individual circuits. Electrical components that work together are shown together. CURRENT FLOW Each drawing is arranged so current flows from positive, at top of page to ground, at bottom. The "hot" labels at the top of a fuse indicate when the ignition switch supplies power to that fuse. CIRCUIT NETWORKING Wires that connect to another circuit are shown with an arrowhead pointing in the direction of current flow. The name of the circuit that shares the wiring is shown for reference. POWER AND GROUND SUPPLY "See Fuse Box Details" indicates there are connections to other circuits that are not shown. All shared circuits are shown on the Fuse Box Details schematic. "See Ground Distribution" indicates there are shared ground circuits which are shown on the ground distribution schematic. CIRCUIT/COMPONENT LOCATION No attempt is made to represent the location or proximity of components. If a wire is actually 4 foot or 4 inches, it will be represented without regard in the schematic. Component/Connector Location and I.D. COMPONENT AND CONNECTOR LOCATION Supplied with the wiring schematic is a component location index. The index lists the correct photograph for the components and connectors listed. The photographs are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. HARNESS ROUTING Harness routing and selected connectors related to the system are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. CONNECTOR I.D. All connectors with more than 2 terminals are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. Fuse Box Details The fuse box details schematic shows all the wiring between a fuse and the components connected to the output side of the fuse. It shows what supplies power to the fuse and when it is energized. Ground Distribution The ground distribution schematics show which components share a common ground point. This information can be very helpful in diagnosing inoperative circuits. If more than one components are not working and they share a common ground, it is likely the ground circuit is faulty. However, if one of the circuits is operative and the other is not, you know the ground and the wire are good up to a splice. Light Switch Details The light switch details schematic shows all the wiring between the light switch/relays and the components connected to the output side of the light switch/relays. Power Distribution The Power distribution schematic shows the wiring from the battery and alternator to the: - Starter solenoid - Fuse box - Light switch - Ignition switch - Fuse link The first component after a fuse link is shown. In certain instances, the first component after a fuse box, fuse and light switch is shown. All fuses in the schematic are "Hot At All Times", since battery voltage is the direct source. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 751 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 753 Symbol Identification Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Clear: CLR Gray: GRY Green: GRN Light Blue: LT BLU Light Green: LT GRN Orange: ORN Pink: PNK Red: RED Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 754 White: WHT Yellow: YEL Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 755 Fuse Block: Diagnostic Aids Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 757 testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Voltage Check Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 760 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 761 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 762 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 766 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 767 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 768 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 770 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Fuse Block: Electrical Diagrams Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 775 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Dash Fuse Box Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Dash Fuse Box (Component Location Index) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 780 Dash Fuse Box (Component Location Index) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Dash Fuse Box (Component Location Index) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > Oxygen Sensor ( O2 ) Lamp <--> [Maintenance Required Lamp/Indicator] > Component Information > Service and Repair Oxygen Sensor ( O2 ) Lamp: Service and Repair OXYGEN SENSOR LIFE INDICATOR LIGHT (O2) RESET PROCEDURE At 90,000 mile intervals, the O2 sensor lamp will illuminate. After replacing the sensor, perform the following procedure to reset the lamp. Maintainence Reminder Light Reset - Remove instrument cluster. - Remove masking tape from hole B. - Remove screw from hole A and install into hole B. - Apply new masking tape to hole A. - Install instrument cluster. NOTE: This procedure assumes that the sensor is being replaced for the first time (at 90,000 miles). For subsequent reset procedure (every 90,000 miles), hole positions will be the opposite of this procedure. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations In the instrument cluster. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 789 Malfunction Indicator Lamp: Description and Operation PURPOSE Illuminates when a influencing occurs that will affect emission control performance. Flashes trouble codes (DTC) during testing operations. LOCATION In the instrument cluster. OPERATION When the system detects a fault in a monitored component and/or circuit, the light will come on and stay on (while the engine is running), alerting the driver to seek service. With intermittent problems, the light may come on and then go out, but a trouble code will be stored in ECM memory if correct parameters are met. The technician can then extract trouble codes from the ECM that will aid in the diagnosis and repair. Another function of the "Check Engine" light is Field Service Mode. When the diagnostic terminal is grounded with the engine running, the system will enter this mode and indicate whether it is in "Open Loop" or "Closed Loop." If in "Open Loop," the "Check Engine" light flashes two and one-half times per second. In "Closed Loop," the light flashes once per second. In "Closed Loop", the light will stay "OFF" most of the time if the system is running too lean. It will stay "ON" most of the time if the system is too rich. While in Field Service Mode, new trouble codes cannot be stored in the ECM memory and the "Closed Loop" timer is bypassed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > CHECK TRANS Indicator <--> [Malfunction Indicator Lamp - A/T] > Component Information > Description and Operation CHECK TRANS Indicator: Description and Operation CIRCUIT DESCRIPTION The "CHECK TRANS" indicator is lit at the beginning of every ignition cycle for 2 to 4 seconds while the TCM performs a self-test of the circuit and components. When the TCM detects an electrical failure in the system (ignition switch on), TCM will turn the "CHECK TRANS" indicator on and store a trouble code in its memory. Note that most electrical failures will cause the TCM to enter the backup mode. The TCM also uses the "CHECK TRANS" indicator to display trouble codes by flashing the indicator. When the Tech-1 is connected to the TCM diagnostic system, the "CHECK TRANS" indicator flashes continuously. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > CHECK TRANS Indicator <--> [Malfunction Indicator Lamp - A/T] > Component Information > Description and Operation > Page 793 CHECK TRANS Indicator: Testing and Inspection CIRCUIT DESCRIPTION The "CHECK TRANS" indicator is lit at the beginning of every ignition cycle for 2 to 4 seconds while the TCM performs a self-test of the circuit and components. When the TCM detects an electrical failure in the system (ignition switch on), TCM will turn the "CHECK TRANS" indicator on and store a trouble code in its memory. Note that most electrical failures will cause the TCM to enter the backup mode. The TCM also uses the "CHECK TRANS" indicator to display trouble codes by flashing the indicator. When the Tech-1 is connected to the TCM diagnostic system, the "CHECK TRANS" indicator flashes continuously. NOTE: This test assumes the following: - Either "CHECK TRANS" indicator is on at all times (ignition is on) and no trouble codes are stored, or - "CHECK TRANS" indicator does not light and the Tech-1 is able to receive data from the TCM. NOTE: For all 1990-93 models: - In addition to its diagnosis-related function, the "CHECK TRANS" indicator will be constantly on (not flashing) if the transmission oil temperature is above 293°F (145°C). - The "CHECK TRANS" indicator will go oft again when the transmission oil temperature is below 257°F (125°C). CIRCUIT DIAGRAM "CHECK TRANS" Circuit Diagram "CHECK TRANS" INDICATOR TEST CHART Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > CHECK TRANS Indicator <--> [Malfunction Indicator Lamp - A/T] > Component Information > Description and Operation > Page 794 "CHECK TRANS" Indicator Test Chart Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tires - Proper Inflation Pressure Information Tires: Technical Service Bulletins Tires - Proper Inflation Pressure Information 2006 Service Bulletins Information IB06-08-S003 Information On Proper Tire Pressure ISSUE DATE: SEPTEMBER 2006 Affected Vehicles All Light Duty Isuzu Vehicles Service Information IMPORTANT: Generally a 5.6°C (10° F) temperature change will result in (is equivalent to) a 1 psi (6.9 kpa) tire pressure change. Tires may be over inflated from the assembly plant due to the mounting process. ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicles placard during the PRE-DELIVERY INSPECTION. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle's tire placard. The tire placard is located on the driver's side front or rear door edge, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 1 psi (6.9 kpa) tire pressure change. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours or driven no more than 1.6 km (1 mi). IMPORTANT: Do not use the tire pressure indicated on the tire itself as a guide. Always inspect and adjust the pressure when the tires are cold. Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tires - Proper Inflation Pressure Information > Page 800 Tires: Technical Service Bulletins Radial Tire - Sidewall Indentations BULLETIN NUMBER SB94-08-001 ISSUE DATE NOVEMBER 1994 GROUP TIRES & WHEELS RADIAL TIRE SIDEWALL INDENTATIONS AFFECTED VEHICLES All Isuzu models equipped with radial tires. SERVICE INFORMATION On some affected vehicles, slight indentations may be noticeable on the sidewall surface of one or more tires, giving the sidewall a wavy appearance. The cause of these indentations lies in a radial tire's construction. In a radial tire, the body ply cords run straight across the tire from bead to bead. Because of this "straight across" construction, the joining of the ply material in the sidewall area may sometimes cause the sidewall surface to develop slight indentations when the tire is inflated. These sidewall indentations are a common characteristic of radial tires and will not affect the tire's performance. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Automatic Locking Hub Wheel Bearing: Adjustments Automatic Locking Hub Fig. 1 Exploded View Of Automatic Locking Hub Assembly 1. Shift transfer lever to the 2H position then move vehicle forward and rearward approximately three feet. 2. Raise and support vehicle, then remove wheel and tire assemblies. 3. Remove hub cap retaining bolts then the hub cap, Fig. 1. 4. Remove housing assembly, snap ring and shims. 5. Remove drive clutch assembly, inner cam and lock washer. 6. Using a spring scale, adjust bearing preload to 3.31 lbs. 7. Install lock washer with larger diameter of the tapered bore to the vehicle. If bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Automatic Locking Hub > Page 805 Wheel Bearing: Adjustments Manual Locking Hub Fig. 2 Exploded View Of Manual Locking Hub Assembly 1. Shift transfer lever to the 2H position and set free wheeling hub into FREE position. 2. Raise and support vehicle, then remove wheel and tire assemblies. 3. Remove housing assembly retaining bolts then the housing assembly, Fig. 2. 4. Remove snap ring and shims. 5. Remove body assembly and lock washer. 6. Using a spring scale, adjust bearing preload to 3.03 lbs. 7. Install lock washer with larger diameter of the tapered bore to the outer side of vehicle. If bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer. 8. Apply Loctite 515 or equivalent, to body assembly and install. 9. Install snap ring and shims, then adjust clearance between free wheeling hub body and snap ring. Clearance should be 0.01 inch. Available adjusting shim are .008, .011, .020 and .039. 10. Align and install cover assembly. Torque bolts to 8.7 ft. lbs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Disassembly Wheel Hub: Service and Repair Disassembly Automatic Locking Hub 1. Remove outer bearing and outer race from hub. 2. Remove oil seal. 3. Using a drift, remove outer bearing race, then the inner bearing. 4. Scribe mark to both rotor and hub, then remove six rotor to hub retaining bolts. 5. Using a hammer, remove wheel studs as required. Manual Locking Hub 1. Remove outer bearing, oil seal and inner bearing. 2. While pushing follower knob, turn clutch assembly clockwise and remove clutch assembly from knob. 3. Remove snap ring, knob, compression spring and follower. 4. Turn clutch assembly retaining spring clockwise and remove from assembly. 5. Remove detent ball and spring. 6. Remove hub lock ring, snap ring, inner assembly, snap ring, ring and spacer. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Disassembly > Page 810 Wheel Hub: Service and Repair Assembly Automatic Locking Hub 1. Install wheel studs if removed. 2. Align scribe marks on hub and rotor, then install six retaining bolts and tighten to specifications. 3. Using bearing installer tools No. J-29015 and J-8092, or equivalents, install outer race. 4. Repeat step 3 for installation of outer bearing and outer race. 5. Install inner bearing, then using seal tools No. J-36830 and J-8092, or equivalent, install oil seal. 6. Coat inner hub with grease, then apply Besco L-2, or equivalent, to inner and outer bearing. 7. Turn hub so chamfer is aligned to tapped hole on outer side, then using installer tool No. J-36827, or equivalent, install hub nut. 8. Using a spring scale, adjust bearing preload to 3.31 lbs. 9. Install lock washer with larger diameter of tapered bore to vehicle. If bolt holes in lock plate are not aligned with corresponding holes in nut, reverse lock plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer. 10. With transfer lever still in 2H position, install inner cam with cam gear facing out. 11. Lower vehicle from hoist, then support lower link with floor jack, placing axle in normal position. Fig. 3 Axle Shaft Snap Ring Tool Installation Fig. 18 Measuring axle shaft snap ring clearance 12. Install snap ring tool No. J-36836, or equivalent, to axle shaft with extension tool No. J-36835-2, or equivalent, Fig. 3, then measure clearance t, Fig. 4, between tool and snap ring groove of axle shaft using a feeler gauge. 13. Clearance should be 0.0039 inches. If clearance is larger than specified, select proper shim to meet specification. 14. Remove tool No. J-36836 and ensure inner cam stays in place. If inner cam is removed, repeat steps 10-13. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Disassembly > Page 811 Fig. 19 Application of drive clutch assembly lubricant (Part 1 of 2) Fig. 19 Application of drive clutch assembly lubricant (Part 2 of 2) 15. Apply multipurpose grease or bearing grease to portions of clutch assembly as shown Fig. 5, then align cut part of drive clutch assembly with concave part of inner cam. 16. Engage cam teeth of drive clutch assembly to teeth of the inner cam by turning axle shaft. 17. Install snap ring and shims as follows: a. Install extension tool No. J-36835-2, or equivalent, to axle, Fig. 6. b. Install snap ring to snap ring tool. c. Install driver tool No. J-36835-1, or equivalent. d. Pull axle shaft out by pulling tool No. J-36835-2 and install snap ring to axle by pushing tool No. J-36835-1, then remove tool. Ensure snap ring is fitted correctly. Fig. 20 Installation of axle snap rings & shims 18. Install housing assembly, hub cap and retaining bolts and tighten to specification. Manual Locking Hub 1. Apply grease to both faces of spacer and install. 2. Apply grease to inside face of ring and install. 3. Install snap ring, then apply grease to splined portion of inner assembly body and install. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Disassembly > Page 812 Fig. 7 Exploded View Of Manual Locking Hub 4. Install snap ring, hub lock ring, detent ball and spring, Fig. 7. 5. Apply grease to outer circumference of knob and inner circumference of cover. 6. Align detent ball with groove of cover and install knob. 7. Install snap ring with smooth surface toward knob. 8. Install clutch assembly retaining spring. 9. Install follower to clutch. Ensure follower nail comes close to bent portion of retaining spring by aligning follower stopper nail to outer teeth of clutch, then hook retaining spring onto upper portion of hanger nails of follower. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Disassembly > Page 813 10. Install compression spring with smaller diameter toward follower. 11. Align follower nail to handle groove, then assemble clutch with knob by pushing and turning clutch counterclockwise to knob. 12. Using installer tools No. J-29015 and J-0092, or equivalents, install two outer races then two outer bearings. 13. Coat hub with grease, then apply Besco L-2, or equivalent, to inner and outer bearing. 14. Turn hub so chamfer is aligned to tapped hole on outer side, then using hub nut tool No. J-36827, or equivalent, install hub nut. 15. Using a spring scale, adjust bearing preload to 3.03 lbs. 16. Install lock washer with larger diameter of tapered bore to outer side of vehicle. If bolt holes in lock plate are not aligned with corresponding holes in nut, reverse lock plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer. 17. Apply Loctite 515, or equivalent, to body assembly and install. 18. Install snap ring and shims, then adjust clearance between free wheeling hub body and snap ring. Clearance should be 0.01 inch. Available adjusting shim are 0.008, 0.011, 0.020 and 0.039. 19. Align and install cover assembly, tightening to specifications. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Disassembly > Page 814 Wheel Hub: Service and Repair Automatic Locking Hub Service 1. Shift transfer lever to 2H position, then move vehicle forward and rearward approximately three feet. 2. Raise and support vehicle, then remove wheel and tire assemblies. 3. Disconnect brake hose from caliper. 4. Remove caliper locking bolt. 5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly 6. Remove brake pad support bracket. Fig. 1 Exploded View Of Automatic Locking Hub Assembly 7. Remove hub cap retaining bolts, then the hub cap, Fig. 1. 8. Remove housing assembly, snap ring and shims. 9. Remove drive clutch assembly, inner cam and lock washer. 10. Using removal tool No. J-36827, or equivalent, remove hub nut. 11. Remove hub and disc assembly. 12. Reverse procedure to install. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Disassembly > Page 815 Wheel Hub: Service and Repair Manual Locking Hub Service 1. Shift transfer lever to 2H position and set free wheeling hub into Free position. 2. Raise and support vehicle, then remove wheel and tire assemblies. 3. Disconnect brake hose from caliper. 4. Remove caliper locking bolt. 5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly 6. Remove brake pad support bracket. Fig. 2 Exploded View Of Manual Locking Hub Assembly 7. Remove housing assembly retaining bolts then the housing assembly, Fig. 2. 8. Remove snap ring and shims. 9. Remove body assembly and lock washer. 10. Using removal tool No. J-36827, or equivalent, remove hub nut. 11. Remove hub and disc assembly. 12. Reverse procedure to install. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Locking Hub - Special Tool Wheel Hub (Locking): Technical Service Bulletins Locking Hub - Special Tool BULLETIN NUMBER SB93-07-003 ISSUE DATE August 1993 GROUP PROPELLER SHAFT & AXLE LOCKING FRONT HUBS SPECIAL TOOL IDENTIFICATION AFFECTED VEHICLES 1988-91 Trooper II (KT), 1992-93 Trooper (UX), 1988-93 Pickup (TF) and Amigo (TC), and 1991-93 Rodeo (UC) models equipped with 4-wheel drive. SERVICE INFORMATION The locking front hub outer bearing, outer race installer (special tool) is incorrectly identified in 1988-93 Workshop Manuals for affected vehicles. The correct special tool number for the locking front hub outer bearing, outer race installer is J-29015. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Automatic Locking Hub Wheel Hub (Locking): Service and Repair Automatic Locking Hub DISASSEMBLY 1. Remove outer bearing and outer race from hub. 2. Remove oil seal, then using a drift, remove outer bearing race then the inner bearing. 3. Apply a scribe mark to both rotor and hub, then remove six rotor to hub retaining bolts. 4. Using a hammer, remove wheel studs as required. ASSEMBLY 1. Install wheel studs if removed. 2. Align scribe marks on hub and rotor then install six retaining bolts and torque to 76 ft. lbs. 3. Using tools J-36828 and J-8092 or equivalent, install outer race. 4. Repeat step 3 for installation of outer bearing and outer race. 5. Install inner bearing, then using tools J-36828 and J-8092 or equivalent, install oil seal. 6. Coat inner hub with grease, then apply Besco L-2 or equivalent to inner and outer bearing. 7. Turn hub so chamfer is aligned to the tapped hole on outer side, then using tool J-36827 or equivalent, install hub nut. 8. Using a spring scale, adjust bearing preload to 3.31 lbs. 9. Install lock washer with larger diameter of the tapered bore to the vehicle. If bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer. 10. With transfer lever still in the ``2H'' position, install inner cam with cam gear facing out. 11. Lower vehicle from hoist, then support lower link with floor jack placing axle in normal position. Fig. 17 Exploded View Of Automatic Locking Hub Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Automatic Locking Hub > Page 822 Fig. 18 Measuring axle shaft snap ring clearance 12. Install tool J-36836 to axle shaft by tool J-36835-2 or equivalent, Fig. 17, then measure clearance ``t'' Fig. 18, between tool and snap ring groove of axle shaft using a feeler gauge. 13. Clearance should be .0039. If clearance is larger than specified, select proper shim to meet specification. 14. Remove tool J-36836 and ensure inner cam stays in place. If inner cam is removed, repeat steps 10-13. Fig. 19 Application of drive clutch assembly lubricant (Part 1 of 2) Fig. 19 Application of drive clutch assembly lubricant (Part 2 of 2) Fig. 20 Installation of axle snap rings & shims 15. Apply multipurpose grease or bearing grease to portions of clutch assembly as shown in Fig. 19, then align cut part of drive clutch assembly with the concave part of inner cam. 16. Engage cam teeth of drive clutch assembly to that of the inner cam by turning axle shaft. 17. Install snap ring and shims as follows: a. Install tool J-36835-2 or equivalent, to axle Fig. 20. b. Install snap ring to snap ring tool. c. Install tool driver J-36835-1 or equivalent. d. Pull axle shaft out by pulling tool J-36835-2 and install snap ring to axle by pushing tool J-36835-1, then remove tool. Ensure snap ring is Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Automatic Locking Hub > Page 823 fitted correctly. 18. Install housing assembly, hub cap and retaining bolts and torque to 43.4 ft. lbs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Automatic Locking Hub > Page 824 Wheel Hub (Locking): Service and Repair Manual Locking Hub DISASSEMBLY 1. Remove outer bearing, oil seal and inner bearing. 2. While pushing follower knob, turn clutch assembly clockwise and remove clutch assembly from knob. 3. Remove snap ring, knob, compression spring and follower. 4. Turn clutch assembly retaining spring clockwise and remove from assembly. 5. Remove detent ball and spring. 6. Remove hub lock ring, snap ring, inner assembly, snap ring, ring and spacer. Fig. 21 Exploded view of manual locking hub. ASSEMBLY 1. Apply grease to both faces of spacer and install. 2. Apply grease to inside face of ring and install. 3. Install snap ring, then apply grease to splined portion of inner assembly body and install. 4. Install snap ring, hub lock ring, detent ball and spring, Fig. 21. 5. Apply grease to outer circumference of knob and inner circumference of cover. 6. Align detent ball with groove of cover and install knob. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Automatic Locking Hub > Page 825 7. Install snap ring with smooth surface toward knob. 8. Install clutch assembly retaining spring. 9. Install follower to clutch. Ensure follower nail comes close to the bent portion of retaining spring by aligning follower stopper nail to outer teeth of clutch, then hook retaining spring onto upper portion of hanger nails of follower. 10. Install compression spring with smaller diameter toward follower. 11. Install clutch assembly as follows: a. Align follower nail to handle groove then assemble clutch with knob by pushing and turning clutch counterclockwise to knob. 12. Using tools J-36828 and J-8092 or equivalent, install two outer races then two outer bearings. 13. Coat hub with grease, then apply Besco L-2 or equivalent to inner and outer bearing. 14. Turn hub so chamfer is aligned to the tapped hole on outer side, then using tool J-36827 or equivalent, install hub nut. 15. Using a spring scale, adjust bearing preload to 3.03 lbs. 16. Install lock washer with larger diameter of the tapered bore to the outer side of vehicle. If bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer. 17. Apply Loctite 515 or equivalent, to body assembly and install. 18. Install snap ring and shims, then adjust clearance between free wheeling hub body and snap ring. Clearance should be 0.01 inch. Available adjusting shim are .008, .011, .020 and .039. 19. Align and install cover assembly torquing bolts to 8.7 ft. lbs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Automatic Locking Hub > Page 826 Wheel Hub (Locking): Service and Repair Removal and Installation Fig. 15 Exploded view of automatic locking hub assembly Automatic Locking Hub 1. Shift transfer lever to the ``2H'' position, then move vehicle forward and rearward approximately three feet. 2. Raise and support vehicle, then remove wheel and tire assemblies. 3. Disconnect brake hose from caliper. 4. Remove caliper locking bolt. 5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly 6. Remove brake pad support bracket. 7. Remove hub cap retaining bolts, then the hub cap, Fig. 15. 8. Remove housing assembly, snap ring and shims. 9. Remove drive clutch assembly, inner cam and lock washer. 10. Using tool J-36827 or equivalent, remove hub nut. 11. Remove hub and disc assembly. Fig. 16 Exploded view of manual locking hub assembly Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Automatic Locking Hub > Page 827 Manual Locking Hub 1. Shift transfer lever to the ``2H'' position and set free wheeling hub into Free position. 2. Raise and support vehicle, then remove wheel and tire assemblies. 3. Disconnect brake hose from caliper. 4. Remove caliper locking bolt. 5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly 6. Remove brake pad support bracket. 7. Remove housing assembly retaining bolts then the housing assembly Fig. 16. 8. Remove snap ring and shims. 9. Remove body assembly and lock washer. 10. Using tool J-36827 or equivalent, remove hub nut. 11. Remove hub and disc assembly. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Wheel Lug - Torque Stick Now Used for Installation Wheel Fastener: Technical Service Bulletins Wheel Lug - Torque Stick Now Used for Installation BULLETIN NUMBER: SB99-14-S008 ISSUE DATE: MAY 1999 GROUP: STANDARD TOOLS 3/4" (19 mm) WHEEL LUG TORQUE STICK AFFECTED VEHICLES All Isuzu models (exduding Hombre) equipped with 3/4" (19 mm) wheel lug nuts. ESSENTIAL TOOL INFORMATION To prevent over-tightening wheel lugs on Isuzu passenger vehicles, American Isuzu Motors Inc. is making essential a 3/4" (19 mm) wheel lug torque stick. This new tool # J-44342 must now be used for the installation of steel/aluminum wheels on all Isuzu passenger vehicle wheels, excluding Hombre MY96-99, I-Mark MY87-89, and P'UP MY87. The torque stick is preset to Isuzu factory specifications and is an Isuzu essential tool. Tool number J-44342 will be shipped free of charge to all Isuzu SUV dealerships in June 1999. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection 1. Start and warm engine to operating temperature. 2. Remove all spark plugs and apply a few drops of engine oil into spark plug holes. 3. Relieve fuel system pressure as outlined under Precautions. 4. Disable ignition system, by removing ignition fuse. 5. Connect a tachometer and crank engine, ensure cranking speed is 300 RPM or higher. 6. Install compression gauge, then crank engine with throttle wide open. 7. Minimum pressure should be 128 psi. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > NHTSA94V132000 > Jul > 94 > Recall 94V132000: Camshaft Seal End Plug Defect Camshaft: All Technical Service Bulletins Recall 94V132000: Camshaft Seal End Plug Defect CONSTANT EXPANSION AND CONTRACTION OF THE CYLINDER HEAD CAUSES THE CAMSHAFT SEAL END PLUG CAN BECOME DISLODGED FROM THE CYLINDER HEAD. THIS ALLOWS OIL TO LEAK FROM THE CAMSHAFT. THIS CAN CAUSE ENGINE DAMAGE AND POSSIBLE ENGINE FIRE FROM OIL LEAKING ONTO THE HOT EXHAUST SYSTEM. DEALERS WILL INSTALL CAMSHAFT END SEAL PLUG RETAINER PLATES. SYSTEM: ENGINE; CAMSHAFT. VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES EQUIPPED WITH ISUZU 6VDI ENGINES. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE, OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NON-COMPLIANCE, PLEASE CONTACT ISUZU SERVICE CENTER AT 1-800-255-6727 OR HONDA SERVICE CENTER AT 1-800-999-1009. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1992 ISUZU TRUCK TROOPER 1993 ISUZU TRUCK RODEO 1993 ISUZU TRUCK TROOPER 1994 HONDA TRUCK PASSPORT 1994 ISUZU TRUCK RODEO 1994 ISUZU TRUCK TROOPER Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Recalls for Camshaft: > NHTSA94V132000 > Jul > 94 > Recall 94V132000: Camshaft Seal End Plug Defect Camshaft: Recalls Recall 94V132000: Camshaft Seal End Plug Defect CONSTANT EXPANSION AND CONTRACTION OF THE CYLINDER HEAD CAUSES THE CAMSHAFT SEAL END PLUG CAN BECOME DISLODGED FROM THE CYLINDER HEAD. THIS ALLOWS OIL TO LEAK FROM THE CAMSHAFT. THIS CAN CAUSE ENGINE DAMAGE AND POSSIBLE ENGINE FIRE FROM OIL LEAKING ONTO THE HOT EXHAUST SYSTEM. DEALERS WILL INSTALL CAMSHAFT END SEAL PLUG RETAINER PLATES. SYSTEM: ENGINE; CAMSHAFT. VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES EQUIPPED WITH ISUZU 6VDI ENGINES. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE, OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NON-COMPLIANCE, PLEASE CONTACT ISUZU SERVICE CENTER AT 1-800-255-6727 OR HONDA SERVICE CENTER AT 1-800-999-1009. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1992 ISUZU TRUCK TROOPER 1993 ISUZU TRUCK RODEO 1993 ISUZU TRUCK TROOPER 1994 HONDA TRUCK PASSPORT 1994 ISUZU TRUCK RODEO 1994 ISUZU TRUCK TROOPER Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Page 851 Camshaft: Specifications Camshaft Journal Diameter ................................................................................................................. ................................................. 1.7692-1.7701 inches Maximum Journal Runout .............................. .................................................................................................................................................. 0.0039 inches Camshaft Bearing Clearance ................................................................................................... ............................................................. 0.0016-0.0043 inches Camshaft Endplay .............................. .................................................................................................................................................. 0.0028-0.0079 inches Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Page 852 Camshaft: Service and Repair 1. Relieve fuel system pressure as outlined under Technician Safety Information. On models with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then insulate cable end with electrical tape, or equivalent. 3. Remove air cleaner assembly. 4. Remove upper and lower radiator fan shroud from radiator. 5. Remove cooling fan assembly, then disconnect accelerator cable from throttle body. 6. Mark position of vacuum hoses for installation, then remove from common chamber and throttle body. 7. Mark position of electrical connectors for installation, then disconnect connectors from common chamber. 8. Disconnect spark plug wires from valve covers, then the three electrical connectors from DIS module. 9. Remove DIS module and spark plug wires as an assembly. 10. Remove EGR valve assembly, then the common chamber. 11. Disconnect fuel supply and return hoses from fuel rail assembly. 12. Remove drive belts, then power steering pump. Do not disconnect pressure lines from power steering pump. 13. Remove fan pulley assembly, then the timing belt. 14. Remove valve cover, then the camshaft pulley. 15. Remove front plate, then the camshaft retaining bracket. 16. Remove camshaft, then the rocker arm assembly. Fig. 47 Rocker Arm Assembly Tightening Sequence 17. Reverse procedure to install, noting the following: a. Using sequence shown in Fig. 47, torque rocker arm assembly retaining bolts to 13 ft. lbs. b. Torque camshaft bracket retaining bolt M8 to 13 ft. lbs., then the camshaft bracket retaining bolt M6 to 6 ft. lbs. c. Tighten front plate retaining bolts to specification. d. Tighten camshaft pulley retaining bolts to specification. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 861 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 862 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 863 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 864 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. Lifter / Lash Adjuster: All Technical Service Bulletins Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. BULLETIN NUMBER SB95-01-L006 ISSUE DATE SEPTEMBER 1995 GROUP ENGINE TROOPER (UX) AND RODEO (UC) SOHC HYDRAULIC VALVE LIFTER PRIMING (Supersedes SB95-01-L003) AFFECTED VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION Hydraulic valve lifters on 6VD1 SOHC engines are self-bleeding. However, when a lifter is replaced, it should be primed (i.e., filled with oil and purged of excess air) before it is reinstalled into its rocker arm, to minimize initial valve noise and ensure proper operation. This Service Bulletin addresses the priming of a replacement SOHC hydraulic valve lifter. REMOVAL 1. Hydraulic Valve Lifter and Rocker Arm Remove old hydraulic valve lifter and rocker arm in accordance with appropriate Workshop Manual. - Carefully separate new hydraulic valve lifter from its rocker arm. INSTALLATION 1. Hydraulic Valve Lifter and Rocker Arm - Push in check ball on underside of lifter, using small diameter rod (2 mm/.O8 in), and submerge new lifter in clean engine oil. Be sure to wear suitable gloves to protect hands from engine oil. - Pump plunger (located on top of lifter) to fill lifter with oil and purge it of excess air. Keep pumping plunger until no air bubbles are visible in engine oil and plunger becomes hard. - When no air bubbles are visible, and the plunger is hard, remove the rod to release the check ball. IMPORTANT: Each hydraulic valve lifter and rocker arm are an integrated set. Do not mix these parts during reinstallation. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. > Page 869 - Submerge new rocker arm in clean engine oil and install primed lifter into rocker arm. - Remove assembly from engine oil and install onto rocker arm shaft in accordance with appropriate Workshop Manual. FLAT RATE MANUAL INFORMATION Use existing Flat Rate Manual labor operation number 010247 (right side) or 01A247 (left side). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 875 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 876 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 877 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 878 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Lifter / Lash Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. Lifter / Lash Adjuster: All Technical Service Bulletins Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. BULLETIN NUMBER SB95-01-L006 ISSUE DATE SEPTEMBER 1995 GROUP ENGINE TROOPER (UX) AND RODEO (UC) SOHC HYDRAULIC VALVE LIFTER PRIMING (Supersedes SB95-01-L003) AFFECTED VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION Hydraulic valve lifters on 6VD1 SOHC engines are self-bleeding. However, when a lifter is replaced, it should be primed (i.e., filled with oil and purged of excess air) before it is reinstalled into its rocker arm, to minimize initial valve noise and ensure proper operation. This Service Bulletin addresses the priming of a replacement SOHC hydraulic valve lifter. REMOVAL 1. Hydraulic Valve Lifter and Rocker Arm Remove old hydraulic valve lifter and rocker arm in accordance with appropriate Workshop Manual. - Carefully separate new hydraulic valve lifter from its rocker arm. INSTALLATION 1. Hydraulic Valve Lifter and Rocker Arm - Push in check ball on underside of lifter, using small diameter rod (2 mm/.O8 in), and submerge new lifter in clean engine oil. Be sure to wear suitable gloves to protect hands from engine oil. - Pump plunger (located on top of lifter) to fill lifter with oil and purge it of excess air. Keep pumping plunger until no air bubbles are visible in engine oil and plunger becomes hard. - When no air bubbles are visible, and the plunger is hard, remove the rod to release the check ball. IMPORTANT: Each hydraulic valve lifter and rocker arm are an integrated set. Do not mix these parts during reinstallation. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Lifter / Lash Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. > Page 884 - Submerge new rocker arm in clean engine oil and install primed lifter into rocker arm. - Remove assembly from engine oil and install onto rocker arm shaft in accordance with appropriate Workshop Manual. FLAT RATE MANUAL INFORMATION Use existing Flat Rate Manual labor operation number 010247 (right side) or 01A247 (left side). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Tighten rocker arm shafts bolts in sequence (13 lb ft.) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Disassembly and Assembly Connecting Rod: Service and Repair Disassembly and Assembly CONNECTING RODS 1. Check the connecting rod alignment with a connecting rod alignment tool (Fig 6A-120) If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. 2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the big end of the connecting rod (Fig. 6A-121). If the clearance exceeds the specified limit, the connecting rod must be replaced. 3. Measure the oil clearance between the connecting rod and the crankshaft by: 1) Remove the connecting rod cap nuts and the rod caps. Arrange the removed rod caps in the cylinder number order. 2) Clean the rod bearings and the crankshaft pins. 3) Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastigage to the crank pin (Fig. 6A-122). 4) Reinstall the rod caps to their original positions. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Disassembly and Assembly > Page 893 TIGHTEN THE ROD CAPS. (6VD1) Torque: N.m (lb.ft) 54 (40) NOTE: Do not allow the crankshaft to rotate. 5) Remove the rod caps. 6) Measure the width of the plastigage and determine the oil clearance. It the oil clearance exceeds the limit, replace the rod bearing as a set (Fig. 6A-123). 7) Clean the plastigage from the bearings and the crankshaft pins. CON-ROD BEARING SELECTION (Fig. 6A-124) Select the install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark. NOTE: Take care not to confuse the alignment mark and the size mark during the installation procedure. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Disassembly and Assembly > Page 894 Connecting Rod: Service and Repair Piston and Connecting Rod Fig. 53 Piston & connecting rod assembly Assemble piston to piston rod as shown in Fig. 53. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft: Standard Journal Diameter: Main Bearing ....................................................................................................................................... ................................ 2.5165-2.5170 inches Crank Pin ........................................................................ ..................................................................................................... 2.1229-2.1235 inches Out Of Round, All ................................................................................................................................ .................................................. 0.0002 inches Taper, All ................................................................... ............................................................................................................................ 0.0002 inches Endplay ................................................................................................................................................ ...................................... 0.0020-0.0090 inches Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 898 Crankshaft: Service and Repair DISASSEMBLY 1. Cylinder head assembly 2. Oil pan Note: Do not to damage or deform the sealing flange surface of oil pan. 3. Oil pipe and rubber ring 4. Oil strainer and rubber ring 5. Oil pump assembly 6. Crankcase side bolts 7. Oil gallery 8. Piston and connecting rod assembly 9. Flywheel 10. Rear oil seal retainer 11. Main bearing cap 12. Crankshaft INSPECTION AND REPAIR Crankshaft Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 899 - Thrust clearance - set the dial indicator as shown in the illustration and measure the crankshaft thrust clearance. - If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set. Crankshaft Inspection - Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. - Inspect the ports for obstructions INSPECTION AND REPAIR 1. Carefully set the crankshaft on the V-blocks. Slowly rotate the crankshaft and measure the runout. If the crankshaft runout exceeds the specified limit, the crankshaft must be replaced (Fig. 6A-70). 2. Measure the diameter and the uneven wear of the main journal and crankpin (Fig. 6A-71). If the crank wear exceeds the specified limit, replace crankshaft. Main Bearing Clearance 1. Remove the bearing caps and measure the oil clearance. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 900 2. Remove the main bearing caps in the sequence shown in the illustration (Fig. 6A-72). Arrange the removed main bearing caps in the cylinder number order. 3. Remove the crankshaft. Remove the main bearings. 4. Clean the upper and lower bearings as well as the crankshaft main journal. 5. Check the bearings for damage or excessive wear. The bearings must be replaced as a set if damage or excessive wear is discovered during inspection. 6. Set the upper bearings and the thrust washers to their original positions. Carefully install the crankshaft. 7. Set the lower bearings to the bearing cap original position. 8. Apply plastigage to the crankshaft journal unit as shown in the illustration (Fig. 6A-73). Note: Do not set the plastigage on the oil hole. 9. Install main bearing caps, oil gallery and crank case bolts in the order shown, and tighten each bolt to the specified torque (Fig. 6A-74). Note: Do not Apply engine oil to the crank case side bolts. - Main bearing caps bolts torque N.m (lb.ft) 39 (29) - Oil gallery fixing bolts: 1st step N.m (lb.ft) 29 (22) 2nd step 55° - 65° - Crank case side bolts torque N.m (lb.ft) 39 (29) Note: Do not allow the crankshaft to rotate. 10. Remove the main bearing caps. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 901 11. Measure the plastigage width and determine the oil clearance. If the oil clearance exceeds the specified limit, replace the main bearings as a set and/or replace the crankshaft (Fig. 6A-75). 12. Clean the plastigage from the bearings and the crankshaft. Remove the crankshaft and the bearings. CRANKSHAFT BEARING SELECTION - When installing new crankshaft bearings or replacing bearings, refer to the selection table below. - Select and install the new crankshaft bearings, paying close attention to the cylinder body journal hole (1) diameter size mark and the crankshaft journal (2) diameter size mark (Fig. 6A-77, Fig. 6A-79). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 902 Note: Take care to ensure the bearings are positioned correctly. (Fig. 6A-82) REASSEMBLY 12. Crankshaft - Install the main bearings to the cylinder body and the main bearing caps. - Be sure that they are positioned correctly (Fig. 6A-83). - Apply new engine oil to the upper and lower main bearing faces. - Carefully mount the crankshaft. - Apply engine oil to the thrust washer. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 903 - Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft (Fig. 6A-84). 11. Main bearing cap - Apply engine oil to the threads and the seating faces of the bolts. - Install bearing caps in the order shown with the No.1 as the front most bearing cap (Fig. 6A-85). - Semi-tighten all of the bolts. - Finally, tighten all the bolts to specification in the order shown (Fig. 6A-86). Torque N.m (lb.ft) 39 (29) - After the final tightening, check to see that the crankshaft rotates smoothly. 10. Rear oil seal - Remove the oil from the cylinder block and the retainer mounting surface. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 904 - Apply sealant (TB-1207B) or equivalent) to the retainer mounting surface, as shown in the illustration (Fig. 6A-87). - Apply engine oil to the oil seal lip. - Align the cylinder body dowel pin holes with the rear retainer dowel pins. - Tighten the rear retainer fixing bolts. New bolts should be used when installing rear retainer. Torque N.m (lb.ft) 18 (13) Note: Be very careful not to disengage the oil seal garter spring during installation of the rear retainer. If the seal was removed from retainer for replacement, apply engine oil to the oil seal lip and install the oil seal using installer (Fig. 6A-88). Installer; J-39201 9. Flywheel 1) Thoroughly clean and remove the oil from the threads of crankshaft. 2) Remove the oil from the crankshaft and flywheel mounting faces. 3) Mount the flywheel on the crankshaft and then install the washer. 4) Holding the crankshaft to prevent from rotating, tighten bolts in the order shown to the specified torque (Fig. 6A-89). Torque N.m (lb.ft) 54 (40) Note: Do not reuse the bolts. Do not apply the oil or thread lock to the bolts. 8. Piston and connecting rod assembly - Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 905 - Check to see that the piston ring end gaps are correctly positioned (Fig. 6A-90). - Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. - The front marks must be facing the front of the engine (Fig. 6A-91). - Match the numbered caps with the numbers on the connecting rods. Align the punched marks on the connecting rods and caps. - Apply engine oil to the threads and seating faces of the nuts. Tighten the nuts torque N.m (lb.ft) 54 (40) - After tightening the cap nuts, check to see that the crankshaft rotates smoothly. 7. Oil gallery - Tighten the bolts in 2 steps, in the order shown (Fig. 6A-92). - 1st step N.m (lb.ft) 29 (22) 2nd step 55° - 65° 6. Crankcase side bolts Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 906 - Tighten all the bolts to specification in the order shown (Fig. 6A-93). Torque N.m (lb.ft) 39 (29) Note: Do not apply engine oil to the crankcase side bolts. 5. Oil pump assembly 4. Oil strainer and rubber ring 3. Oil pipe and rubber ring - Tighten the bolts Torque N.m (lb.ft) 19 (14) 2. Oil pan 1) Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2) Apply a correct width bead of sealant (TB-1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead (Fig. 6A-94). 3) The oil pan must be installed within 30 minutes after sealant application. 4) Tighten the bolts and nuts to the specified torque N.m (lb.in) 10 (87) 1. Cylinder head assembly Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Camshaft Pulley Retaining Bolts 41 ft.lb Crankshaft Pulley 123 ft.lb Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter ................................................................................................................................... ............................................................................ [01] Piston Clearance ............................................. .................................................................................................................................................... 0.004 inches Piston Pin Diameter ................................................................................................................. ............................................................ 0.8660-0.8650 inches Piston Pin To Piston Clearance ............................................................................................................................................................ 0.0008-0.0016 inches Piston Ring End Gap: Comp. .................................................................................................................................................. .................................................................. [02] Oil .............................................................................. ................................................................................................................ 0.0059-0.0177 inches Piston Ring Side Clearance: Comp. .................................................................................................................................................. ...................................... 0.0010-0.0026 inches [01] -- Piston grade (A), 3.6752-3.6756 inches; (B) 3.6756-3.6760 inches; (C) 3.6760-3.6764 inches. [02] -- Top compression ring, 0.00138-0.0185 inch; second ring, 0.0177-0.0236 inch. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 913 Piston: Service and Repair Fig. 53 Piston & connecting rod assembly Assemble piston to piston rod as shown in Fig. 53. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Diameter ................................................................................................................................... ............................................................................ [01] Piston Clearance ............................................. .................................................................................................................................................... 0.004 inches Piston Pin Diameter ................................................................................................................. ............................................................ 0.8660-0.8650 inches Piston Pin To Piston Clearance ............................................................................................................................................................ 0.0008-0.0016 inches Piston Ring End Gap: Comp. .................................................................................................................................................. .................................................................. [02] Oil .............................................................................. ................................................................................................................ 0.0059-0.0177 inches Piston Ring Side Clearance: Comp. .................................................................................................................................................. ...................................... 0.0010-0.0026 inches [01] -- Piston grade (A), 3.6752-3.6756 inches; (B) 3.6756-3.6760 inches; (C) 3.6760-3.6764 inches. [02] -- Top compression ring, 0.00138-0.0185 inch; second ring, 0.0177-0.0236 inch. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair Piston Ring: Service and Repair Piston Ring - Install the piston rings with the piston ring expander. - The compression ring must be set with the T mark facing up. - Install piston rings in the following sequence. 1. Oil ring (1).Expander ring (2).Upper side rail (3).Lower side rail 2. 2nd Compression ring 3. 1st compression ring - The compression rings must be set with the T or T2 mark facing up. - 1st compression ring: T - 2nd compression ring: T2 - After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 929 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 930 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 931 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 932 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 938 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 939 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 940 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 941 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 942 Valve Clearance: By Symptom Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 943 None: This is not a warranty matter (see POSSIBLE CAUSE). Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 944 Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 945 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 946 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 947 AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 948 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 949 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 950 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 951 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Page 952 Valve Clearance: Specifications Stem Diameter: Intake ................................................................................................................................................... ...................................... 0.2346-0.2323 inches Exhaust ..................................................................... ................................................................................................................. 0.2343-0.2323 inches Face Angle, Degrees ........................................................................................................................... ............................................................................... 45 Valve Clearance: Intake ................................................................................................................................................... .................................................................. [01] Exhaust ...................................................................... ............................................................................................................................................ [01] [01] -- Hydraulic lifters, no adjustment is necessary. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Technical Service Bulletins > Page 953 Valve Clearance: Adjustments These engines use hydraulic valve lifters. No valve adjustment is possible. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Replace all pipes with the same pipe and fittings that were removed. Do not reuse "O" rings. Always replace. - Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair. - Adhere to all Notices and Cautions. NOTE: If available, use system bleed valve (schrader) to relieve pressure. NYLON FUEL PIPE CAUTIONS: In order to reduce the risk of fire and personal injury observe the following items: - Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes - Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115° C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 957 Fuel Pressure Release: Service and Repair 1. Remove fuel filler cap. 2. Remove fuel pump relay from underhood relay center. 3. Start engine and allow to stall. 4. Crank engine for an additional 30 seconds. 5. Remove negative battery cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Tighten rocker arm shafts bolts in sequence (13 lb ft.) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Cylinder Head Cover - Installation Precautions Valve Cover: Technical Service Bulletins Cylinder Head Cover - Installation Precautions BULLETIN NUMBER SB94-01-003 ISSUE DATE DECEMBER 1994 GROUP ENGINE TROOPER (UX) AND RODEO (UC) CYLINDER HEAD COVER DAMAGE AFFECTED VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VDl engine. SERVICE INFORMATION When reinstalling cylinder head covers on affected vehicles, care must be taken to ensure that the head cover bolts are properly tightened. Use only a good quality torque wrench and tighten only to the specifications listed in the appropriate Workshop Manual. Do not use air impact wrenches to tighten cylinder head cover bolts. Air wrenches tighten the bolt until the corner tab on the cylinder head cover either cracks or breaks (Figure 1). Once the tab is damaged, an oil leak will result. This damage can be incorrectly diagnosed as a leaking head gasket or a rear main oil seal. Cracked or broken cylinder head covers due to over tightening are not covered under warranty. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Hand Side Valve Cover: Service and Repair Left Hand Side REMOVAL Preparation: Remove battery ground cable 1. Ignition wire - Disconnect from spark plug side. 2. Positive Crankcase Ventilation hose and Vacuum hose - Disconnect from common chamber. - Disconnect vacuum hose from throttle body. 3. Engine harness bracket - Remove fixing bolts on cylinder head cover. 4. Exhaust Gas Recirculation (EGR) pipe - Remove fixing bolts on cylinder head cover. - Remove two fixing bolts on exhaust manifold. - Remove two valve fixing bolts on common chamber. 5. Cylinder head cover - Remove 11 fixing bolts then the cylinder head cover. INSTALLATION Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Hand Side > Page 967 Fig. 6A1-3 5. Cylinder head cover - Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-1207b or equivalent) of bead diameter 2-3 mm at four places of arched area of camshaft brackets on front and rear sides (Fig.6A1-3). - Tighten cylinder head cover bolts to the specified torque above. 4. Exhaust Gas Recirculation (EGR) pipe. Tighten each fixing bolt to the specified torque above. 3. Engine harness bracket 2. Positive Crankcase Ventilation hose and vacuum hose 1. Ignition wire Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Hand Side > Page 968 Valve Cover: Service and Repair Right Hand Side REMOVAL Preparation: Remove battery ground Gable 1. Common chamber See: Intake Manifold/Service and Repair 2. Ventilation hose - Disconnect from cylinder head cover. 3. Fuel hose - Disconnect feed and return hoses from fuel pipes. - Remove two fuel hose fixing bolts on the cylinder head cover. 4. Engine hanger - Remove heat protector on exhaust manifold. - Remove bolts and nuts that secure the hanger to the exhaust manifold and cylinder head. 5. Heater pipe - Remove heater pipe fixing bolts from the bracket. 6. Cylinder head cover - Remove 11 fixing bolts, then the cylinder head cover. INSTALLATION 6. Cylinder head cover - Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-12O7B or equivalent) of bead diameter 2- 3 mm to four places of arched area of camshaft brackets on front and rear sides. (Fig. 6A1-5) - Tighten Cylinder head cover bolts to torque of N.m (lb.in) 8 (69) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Hand Side > Page 969 5. Heater pipe Bolt Torque - Tighten bolts to the specified torque above. 4. Engine hanger. Bolt Torque Bolt Nut Torque Nut - Tighten bolts and nuts to the specified torque above. 3. Fuel hose 2. Ventilation hose 1. Common chamber Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Cylinder Head, Valve Guides & Valve Seats Valve Guide: Specifications Cylinder Head, Valve Guides & Valve Seats Cylinder Head Warpage Limit .............................................................................................................. ............................................................. 0.006 inches Valve Guides: Stem To Guide Clearance: Intake ................................................................................................................................................... ................................ 0.2346-0.2323 inches Exhaust ........................................................................... ..................................................................................................... 0.2343-0.2323 inches Valve Seats: Seat Width: Intake ................................................................................................................................................... .................................... 0.044-0.025 inches Exhaust ........................................................................... ......................................................................................................... 0.044-0.025 inches Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Cylinder Head, Valve Guides & Valve Seats > Page 974 Valve Guide: Specifications Valve Clearance Specifications Stem Diameter: Intake ................................................................................................................................................... ...................................... 0.2346-0.2323 inches Exhaust ..................................................................... ................................................................................................................. 0.2343-0.2323 inches Face Angle, Degrees ........................................................................................................................... ............................................................................... 45 Valve Clearance: Intake ................................................................................................................................................... .................................................................. [01] Exhaust ...................................................................... ............................................................................................................................................ [01] [01] -- Hydraulic lifters, no adjustment is necessary. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Cylinder Head Warpage Limit .............................................................................................................. ............................................................. 0.006 inches Valve Guides: Stem To Guide Clearance: Intake ................................................................................................................................................... ................................ 0.2346-0.2323 inches Exhaust ........................................................................... ..................................................................................................... 0.2343-0.2323 inches Valve Seats: Seat Width: Intake ................................................................................................................................................... .................................... 0.044-0.025 inches Exhaust ........................................................................... ......................................................................................................... 0.044-0.025 inches Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length ......................................................................................................................................... ............................................................... 1.913 inches Installed Height .............................................. ...................................................................................................................................................... 1.54 inches Compressed Pressure Pounds, Inch Lbs. ................................................................................ ............................................................................... 45 @ 1.54 Out Of Square Limit ........................... .............................................................................................................................................................. .. 0.087 inches Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Stem Diameter: Intake ................................................................................................................................................... ...................................... 0.2346-0.2323 inches Exhaust ..................................................................... ................................................................................................................. 0.2343-0.2323 inches Face Angle, Degrees ........................................................................................................................... ............................................................................... 45 Valve Clearance: Intake ................................................................................................................................................... .................................................................. [01] Exhaust ...................................................................... ............................................................................................................................................ [01] [01] -- Hydraulic lifters, no adjustment is necessary. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 9301005 > May > 93 > Alternator Belt - Squeaking Noise Drive Belt: All Technical Service Bulletins Alternator Belt - Squeaking Noise BULLETIN NUMBER SB93-01-005 ISSUE DATE May 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) BELT NOISE (COLD START) AFFECTED VEHICLES 1992-93 Trooper (UX) and Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION At cold engine start-up, some affected vehicles may experience a squeaking noise coming from the alternator belt. To eliminate the noise, adjust the alternator belt tension to 110 +/- 10 lbs. Alternator belt tension specifications are incorrectly printed in the following Workshop Manuals: Correct alternator belt tension specifications (cold engine) for referenced Workshop Manuals for 3.2L V6 engine are: Initial Tension 180 +/- 10 lbs. Readjustment Tension 110 +/- 10 lbs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 9301005 > May > 93 > Alternator Belt - Squeaking Noise Drive Belt: Customer Interest Alternator Belt - Squeaking Noise BULLETIN NUMBER SB93-01-005 ISSUE DATE May 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) BELT NOISE (COLD START) AFFECTED VEHICLES 1992-93 Trooper (UX) and Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION At cold engine start-up, some affected vehicles may experience a squeaking noise coming from the alternator belt. To eliminate the noise, adjust the alternator belt tension to 110 +/- 10 lbs. Alternator belt tension specifications are incorrectly printed in the following Workshop Manuals: Correct alternator belt tension specifications (cold engine) for referenced Workshop Manuals for 3.2L V6 engine are: Initial Tension 180 +/- 10 lbs. Readjustment Tension 110 +/- 10 lbs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 998 Drive Belt: Specifications CAUTION: ^ It is strongly advised to use a tension gauge to check the tension of this belt. Checking tension by "feel" of belt is not accurate. Tension should be checked using a tension gauge after installation and break-in (about 1,000 km or 620 miles). ^ Tension readjustment of auto tension belt should be made only once when V-type HM' tension has dropped to 40 lb or less and poly V type's to 50 lb or less after the vehicle's total running mileage of 621 miles. ^ As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge. Depress belt with 98N (22 lb) and make sure that slackness is in the range of 8 - 12mm (0.315 0.472 in). Belt tension range to be targeted for cold setting. using a Borrough drive belt tension gauge. DRIVE BELT ADJUSTMENT TENSION ADJUSTMENT Generator & fan pulley drive belt Loosen generator fixing bolt and adjuster lock bolt. Adjust bolt by turning adjust bolt. After installation, tighten lock bolt to the specified tightening torque. Fixing bolt Lock bolt A/C compressor drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Power steering oil pump drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 999 Drive Belt: Testing and Inspection INSPECTION Check drive belts for wear or damage, and replace with new ones as necessary. Check belts for tension, and adjust as necessary. CAUTION: ^ It is strongly advised to use a tension gauge to check the tension of this belt. Checking tension by "feel" of belt is not accurate. Tension should be checked using a tension gauge after installation and break-in (about 1,000 km or 620 miles). ^ Tension readjustment of auto tension belt should be made only once when V-type HM' tension has dropped to 40 lb or less and poly V type's to 50 lb or less after the vehicle's total running mileage of 621 miles. ^ As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge. Depress belt with 98N (22 lb) and make sure that slackness is in the range of 8 - 12mm (0.315 0.472 in). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1000 Drive Belt: Adjustments Belt tension range to be targeted for cold setting. using a Borrough drive belt tension gauge. DRIVE BELT ADJUSTMENT TENSION ADJUSTMENT Generator & fan pulley drive belt Loosen generator fixing bolt and adjuster lock bolt. Adjust bolt by turning adjust bolt. After installation, tighten lock bolt to the specified tightening torque. Fixing bolt Lock bolt A/C compressor drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Power steering oil pump drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation tighten lock bolt to the specified tightening torque. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Right Side Engine Mount: Service and Repair Right Side 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then raise and support vehicle. 3. Slightly raise engine and support with suitable jack, to remove weight from engine mounts. 4. Remove engine mount nut from bracket. 5. Remove wiring harness bracket attaching bolt, then the engine mount bolts and nuts. 6. Remove engine mount. 7. Reverse procedure to install. Tighten to specifications. 8. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Right Side > Page 1005 Engine Mount: Service and Repair Left Side 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then slightly raise and support engine. 3. Remove engine mount nut from bracket. 4. Remove engine mount bolts and nuts from chassis. 5. Remove engine mount. 6. Reverse procedure to install. Tighten to specifications. 7. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Right Side > Page 1006 Engine Mount: Service and Repair Rear 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then raise and support vehicle. 3. Remove crossmember mounting nuts. 4. Raise transmission slightly for clearance between crossmember and transmission, then remove transmission support bolts and nuts. 5. Remove rear mount. 6. Reverse procedure to install. Tighten to specifications. 7. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure: .................................................................................................................................................. 392 550 kPa (56.9 - 80.4 psi) at 3000 rpm. (Normal operating temperature of about 80°C (176°F).) 1992-93 Oil pressure: ................................................................................................................................................ more than 59 kPa (0.6 kg/cm2 (9 psi) at idle. 3,200 rpm, ................................................................................................................................................... 363 451 kPa (3.7 - 4.6 kg/cm2 (53-65 psi) at (Normal operating temperature of about 80°C (176°F).) 1994-95 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1011 Engine Oil Pressure: Testing and Inspection 1. Check for dirt, gasoline or water in the engine oil. a. Change the oil if dirt, gasoline, or water are present. b. Check the viscosity of the oil. c. Change the oil if the viscosity is outside the specified standard. d. Refer to the Engine Lubrication. 2. Check the engine oil level. - The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. - If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit. 4. Install an oil pressure gage. 5. Start the engine and allow the engine to reach normal operating temperature about 80°C (176°F). 6. Measure the oil pressure. Oil pressure should be: 392 - 550 kPa (56.9 - 80.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the oil pressure gage. 9. Install the oil pressure unit. 10. Start the engine and check for leaks. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting Engine Oil: All Technical Service Bulletins Engine - Oil Usage Testing and Reporting 2007 Service Bulletins TSB SB07-01-S001 ISSUE DATE: JANUARY 2007 Engine Oil Usage Testing and Reporting (This Bulletin Supersedes SB04-01-S004) Affected Vehicles All Light Duty Isuzu Vehicles Service Information This bulletin has been revised to include new mileage information for Ascender, i-280, i-290, i-350, and i-370 vehicles and to update Model Years. Before performing any warranty repairs, based on a customer's complaint of excessive engine oil consumption, the attached Engine Oil Usage Test/Report must be completed in full. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1020 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1021 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1022 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1023 The updated Engine Oil Usage Test / Report is divided into two parts, PROCEDURE # 1 and PROCEDURE # 2. Procedure # 1, the inspection and testing portion of the Engine Oil Usage Test / Report, are eligible for warranty submission. Procedure # 1 warranty claim may only be submitted ONE time per vehicle. Review Procedure # 1 Results and perform the appropriate action. Complete all steps in Procedure #1 before continuing on to Procedure # 2 (if required). Procedure # 2, the validation portion, is NOT reimbursable under warranty. Complete all steps in Procedure # 2. Review Procedure # 2 Results and perform the appropriate action. The Technician, Service Manager and Customer are to acknowledge the findings by signing and dating the bottom of the Engine Oil Usage Test / Report. Attach a copy of the completed report to the back of the Repair Order (R/O) hard copy and provide a copy to the customer. NOTE: 1. Normal authorization procedures must be followed for such repairs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1024 2. Information released on paper and electronic format prior to bulletin release cannot be updated. For the most current and up to date information refer to website. All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the combustion process. As a result, varying rates of oil consumption are accepted as normal in all engines. Oil Consumption The accepted rate of oil consumption for engines used in Ascender, i-280, i-290, i-350, and i-370 vehicles is 1 quart (0.946 liter) in 2,000 miles (3200 km). The accepted rate of oil consumption for engines used in Trooper (UX), Axiom (UP), VehiCROSS (VX), Rodeo (UE), and Rodeo Sport/Amigo (UA) vehicles is 1 quart (0.473 liter) in 1,000 mi (1600 km). IMPORTANT: Always refer to the Isuzu Service Policies and Procedures Manual for specific details on warranty coverage and policies. This rate only applies to personal use vehicles, under warranty, that are driven in a non-aggressive manner and maintained in accordance with the appropriate maintenance schedule, with less than 36,000 miles (58,000 km), driven at legal speeds in an unloaded (for trucks) condition. IMPORTANT: This rate does not apply to vehicles that are driven in an aggressive manner, at high RPM, high speeds, or in a loaded condition (for trucks). Oil consumption for vehicles driven under these conditions will be more. Many factors can affect a customer's concern with oil consumption. Driving habits and vehicle maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether the vehicle in question has abnormal engine oil consumption. Gasket and External Leaks Inspect the oil pan and engine covers for leakage due to overtightened, damaged, or out of place gaskets. Inspect oil lines and fittings for signs of leakage. Improper Reading of the Oil Level Indicator (Dipstick) Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the engine/vehicle that is being checked. IMPORTANT: Refer to the Owner Manual for checking and adding engine oil. Not Waiting Long Enough After Running Engine to Check Oil Level Some engines require more time than others for the oil to drain back into the crankcase. To assure a sufficient amount of oil has drained back to the crankcase, and an accurate reading can be obtained, the vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off, before taking an oil level reading. In order to ensure accurate results, the temperature of the oil should be close to the same temperature as the last time the oil level was checked. Improper Oil Fill After an Oil Change Following an oil change, verify that the proper amount and type of oil was put in the engine and that the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's Manual or Service Manual for information on recommended oil quantity, viscosity, and quality. Aggressive Driving, High Speed or High RPM Driving Aggressive driving and/or continuous driving at high speeds/high RPM will increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected. Towing or Heavy Usage Towing a trailer will increase oil consumption and may cause oil consumption to fall below the normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use application. Large frontal area trailers will further increase the work required from the engine, especially at highway speeds, and thus increases the rate of oil consumption. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1025 Crankcase Ventilation System Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages, restrictions, or damage to the PCV system can result in increased oil use. Oil Dilution (Fuel and Water) On vehicles that are usually driven short distances, less than 5 miles (8 km), especially in colder weather, unburned fuel and condensation generated from cold engine operation may not get hot enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the customer the impression of excessive oil consumption. Engine Temperature If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort, piston rings may stick, and excessive wear may result. Verify that all cooling system components are in proper working order. Engine Wear Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn, damaged or improperly installed valve guides, seals and piston rings will all cause an increase in oil consumption. Disclaimer Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1030 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1031 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1032 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1033 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1039 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1040 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1041 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1042 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting Engine Oil: All Technical Service Bulletins Engine - Oil Usage Testing and Reporting 2007 Service Bulletins TSB SB07-01-S001 ISSUE DATE: JANUARY 2007 Engine Oil Usage Testing and Reporting (This Bulletin Supersedes SB04-01-S004) Affected Vehicles All Light Duty Isuzu Vehicles Service Information This bulletin has been revised to include new mileage information for Ascender, i-280, i-290, i-350, and i-370 vehicles and to update Model Years. Before performing any warranty repairs, based on a customer's complaint of excessive engine oil consumption, the attached Engine Oil Usage Test/Report must be completed in full. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1048 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1049 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1050 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1051 The updated Engine Oil Usage Test / Report is divided into two parts, PROCEDURE # 1 and PROCEDURE # 2. Procedure # 1, the inspection and testing portion of the Engine Oil Usage Test / Report, are eligible for warranty submission. Procedure # 1 warranty claim may only be submitted ONE time per vehicle. Review Procedure # 1 Results and perform the appropriate action. Complete all steps in Procedure #1 before continuing on to Procedure # 2 (if required). Procedure # 2, the validation portion, is NOT reimbursable under warranty. Complete all steps in Procedure # 2. Review Procedure # 2 Results and perform the appropriate action. The Technician, Service Manager and Customer are to acknowledge the findings by signing and dating the bottom of the Engine Oil Usage Test / Report. Attach a copy of the completed report to the back of the Repair Order (R/O) hard copy and provide a copy to the customer. NOTE: 1. Normal authorization procedures must be followed for such repairs. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1052 2. Information released on paper and electronic format prior to bulletin release cannot be updated. For the most current and up to date information refer to website. All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the combustion process. As a result, varying rates of oil consumption are accepted as normal in all engines. Oil Consumption The accepted rate of oil consumption for engines used in Ascender, i-280, i-290, i-350, and i-370 vehicles is 1 quart (0.946 liter) in 2,000 miles (3200 km). The accepted rate of oil consumption for engines used in Trooper (UX), Axiom (UP), VehiCROSS (VX), Rodeo (UE), and Rodeo Sport/Amigo (UA) vehicles is 1 quart (0.473 liter) in 1,000 mi (1600 km). IMPORTANT: Always refer to the Isuzu Service Policies and Procedures Manual for specific details on warranty coverage and policies. This rate only applies to personal use vehicles, under warranty, that are driven in a non-aggressive manner and maintained in accordance with the appropriate maintenance schedule, with less than 36,000 miles (58,000 km), driven at legal speeds in an unloaded (for trucks) condition. IMPORTANT: This rate does not apply to vehicles that are driven in an aggressive manner, at high RPM, high speeds, or in a loaded condition (for trucks). Oil consumption for vehicles driven under these conditions will be more. Many factors can affect a customer's concern with oil consumption. Driving habits and vehicle maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether the vehicle in question has abnormal engine oil consumption. Gasket and External Leaks Inspect the oil pan and engine covers for leakage due to overtightened, damaged, or out of place gaskets. Inspect oil lines and fittings for signs of leakage. Improper Reading of the Oil Level Indicator (Dipstick) Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the engine/vehicle that is being checked. IMPORTANT: Refer to the Owner Manual for checking and adding engine oil. Not Waiting Long Enough After Running Engine to Check Oil Level Some engines require more time than others for the oil to drain back into the crankcase. To assure a sufficient amount of oil has drained back to the crankcase, and an accurate reading can be obtained, the vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off, before taking an oil level reading. In order to ensure accurate results, the temperature of the oil should be close to the same temperature as the last time the oil level was checked. Improper Oil Fill After an Oil Change Following an oil change, verify that the proper amount and type of oil was put in the engine and that the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's Manual or Service Manual for information on recommended oil quantity, viscosity, and quality. Aggressive Driving, High Speed or High RPM Driving Aggressive driving and/or continuous driving at high speeds/high RPM will increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected. Towing or Heavy Usage Towing a trailer will increase oil consumption and may cause oil consumption to fall below the normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use application. Large frontal area trailers will further increase the work required from the engine, especially at highway speeds, and thus increases the rate of oil consumption. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 1053 Crankcase Ventilation System Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages, restrictions, or damage to the PCV system can result in increased oil use. Oil Dilution (Fuel and Water) On vehicles that are usually driven short distances, less than 5 miles (8 km), especially in colder weather, unburned fuel and condensation generated from cold engine operation may not get hot enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the customer the impression of excessive oil consumption. Engine Temperature If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort, piston rings may stick, and excessive wear may result. Verify that all cooling system components are in proper working order. Engine Wear Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn, damaged or improperly installed valve guides, seals and piston rings will all cause an increase in oil consumption. Disclaimer Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Refill, quarts including filter ................................................................................................ ........................................................................... 5.7 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1056 Engine Oil: Fluid Type Specifications Oil Viscosity Engine Oil Type .......................... SG/CC, SG/CD, SG, SF/CC, SF/CD SF, SE/CC, SE/CD or SE Engine Oil Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Oil Cooler - Center Bolt Torque Value Correction Oil Cooler: Technical Service Bulletins Oil Cooler - Center Bolt Torque Value Correction BULLETIN NUMBER SB95-01-L001 ISSUE DATE JUNE 1995 GROUP ENGINE TROOPER (UX) AND RODEO (UC) OIL COOLER CENTER BOLT TORQUE SPECIFICATION (WORKSHOP MANUAL CORRECTION) AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95 Rodeo (UC) models equipped with 6VD1 engine. SERVICE INFORMATION The torque specification for the 6VD1 engine oil cooler center bolt is incorrectly listed as 26 Nm (20 ft.lb.) in the Workshop Manuals: Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Oil Cooler - Center Bolt Torque Value Correction > Page 1061 The correct specification should be 59 Nm (43 ft.lb.) (see shaded area of the page). Ensure this specification is corrected in the referenced Workshop Manual pages. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Page 1062 Oil Cooler: Service and Repair REMOVAL NOTE: Remove battery ground cable 1. Oil filter - Remove using the filter wrench: J-36390, or equivalent. 2. Engine coolant hoses - Disconnect two coolant hoses from oil cooler. 3. Oil cooler - Remove center bolt, then the oil cooler. - Check oil cooler and center bolt for cracks, flaws and other damage, and replace as necessary. INSTALLATION 1. Oil cooler [3] - Clean sealing surfaces of oil cooler and cylinder body. - Install center bolt and oil cooler on the oil cooler adapter, and tighten center bolt to 26 Nm (20 ft. lbs.). 2. Engine coolant hoses [2] 3. Oil filter [1] Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair REMOVAL NOTE: Remove battery ground cable 1. Oil filter - Remove using the filter wrench: J-36390, or equivalent. 2. Engine coolant hoses - Disconnect two coolant hoses from oil cooler. 3. Oil cooler - Remove center bolt, then the oil cooler. - Check oil cooler and center bolt for cracks, flaws and other damage, and replace as necessary. INSTALLATION 1. Oil cooler [3] - Clean sealing surfaces of oil cooler and cylinder body. - Install center bolt and oil cooler on the oil cooler adapter, and tighten center bolt to 26 Nm (20 ft. lbs.). 2. Engine coolant hoses [2] 3. Oil filter [1] Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable from battery, then insulate cable end with electrical tape, or equivalent. 3. Remove oil dipstick from oil tube, then raise and support vehicle. Support rear of vehicle with safety stands. 4. Remove stone guard, then the radiator under fan shroud. 5. Remove suspension crossmembers. 6. Remove flywheel inspection cover. 7. Using Pitman Arm Removal Tool No. J-29107, or equivalent, remove pitman arm from steering gear. 8. Disconnect idler arm from frame member. 9. Support front axle housing with jack, then remove two bolts and nuts from isolators on both sides. Lower axle assembly from vehicle. 10. Remove oil pan retaining bolts, then using Seal Cutter tool No. J-37228, or equivalent, remove oil pan from engine block. Sealant is applied to entire mating surface of oil pan. Do not pry on pan, damage to oil pan flange may result. 11. Reverse procedure to install, noting the following: a. Completely remove all old sealant and oil from oil pan and sealing surface of engine block, then apply a 0.18 inch bead of sealant part No. TB-1207C, or equivalent to sealing surface of oil pan. Oil pan must be installed within 30 minutes of sealant application. 12. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation Oil Pressure Gauge: Technical Service Bulletins Engine Oil Pressure Gauge/Lamp - Operation BULLETIN NUMBER SB93-01-001 ISSUE DATE January 7, 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) ENGINE OIL PRESSURE AFFECTED VEHICLES 1992-93 Trooper (UX) and 1993 Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION Oil pressure gauge readings can vary greatly as oil temperature and engine speed change. A "low" gauge reading at hot idle does not necessarily indicate a lubrication system problem. This Service Bulletin describes oil pressure gauge and oil pressure warning light operation. SERVICE PROCEDURE Oil Pressure Gauge Depending on oil temperature and engine RPM, the normal oil pressure gauge reading can range from 8.5 psi at hot idle to more than 100 psi during cold acceleration (Figure 1). If the engine oil pressure is below 8.5 psi, follow the appropriate Workshop Manual instructions for diagnosis and repair procedures for the lubrication system and/or oil pressure gauge. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 1073 Oil Pressure Warning Light If engine oil pressure falls to 2.8 psi or below during engine operation, the on pressure warning light (Figure 2) will come on. Refer to the appropriate Workshop Manual for lubrication system and/or oil pressure warning light diagnosis and repair procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Circuit Schematics CIRCUIT APPLICATION Circuit schematics break the entire electrical system into individual circuits. Electrical components that work together are shown together. CURRENT FLOW Each drawing is arranged so current flows from positive, at top of page to ground, at bottom. The "hot" labels at the top of a fuse indicate when the ignition switch supplies power to that fuse. CIRCUIT NETWORKING Wires that connect to another circuit are shown with an arrowhead pointing in the direction of current flow. The name of the circuit that shares the wiring is shown for reference. POWER AND GROUND SUPPLY "See Fuse Box Details" indicates there are connections to other circuits that are not shown. All shared circuits are shown on the Fuse Box Details schematic. "See Ground Distribution" indicates there are shared ground circuits which are shown on the ground distribution schematic. CIRCUIT/COMPONENT LOCATION No attempt is made to represent the location or proximity of components. If a wire is actually 4 foot or 4 inches, it will be represented without regard in the schematic. Component/Connector Location and I.D. COMPONENT AND CONNECTOR LOCATION Supplied with the wiring schematic is a component location index. The index lists the correct photograph for the components and connectors listed. The photographs are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. HARNESS ROUTING Harness routing and selected connectors related to the system are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. CONNECTOR I.D. All connectors with more than 2 terminals are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. Fuse Box Details The fuse box details schematic shows all the wiring between a fuse and the components connected to the output side of the fuse. It shows what supplies power to the fuse and when it is energized. Ground Distribution The ground distribution schematics show which components share a common ground point. This information can be very helpful in diagnosing inoperative circuits. If more than one components are not working and they share a common ground, it is likely the ground circuit is faulty. However, if one of the circuits is operative and the other is not, you know the ground and the wire are good up to a splice. Light Switch Details The light switch details schematic shows all the wiring between the light switch/relays and the components connected to the output side of the light switch/relays. Power Distribution The Power distribution schematic shows the wiring from the battery and alternator to the: - Starter solenoid - Fuse box - Light switch - Ignition switch - Fuse link The first component after a fuse link is shown. In certain instances, the first component after a fuse box, fuse and light switch is shown. All fuses in the schematic are "Hot At All Times", since battery voltage is the direct source. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 Symbol Identification Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Clear: CLR Gray: GRY Green: GRN Light Blue: LT BLU Light Green: LT GRN Orange: ORN Pink: PNK Red: RED Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 White: WHT Yellow: YEL Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 Oil Pressure Gauge: Diagnostic Aids Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Voltage Check Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1093 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 Oil Pressure Warning Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Needle Does Not Move Oil Pressure Gauge: Testing and Inspection Needle Does Not Move Fig. 24 Oil Gauge Diagnosis: Needle Does Not Move Refer to Fig. 24, for oil gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1099 Oil Pressure Gauge: Testing and Inspection Gauge Reading Is Too Low Fig. 25 Oil Gauge Diagnosis: Reading Is Too Low Refer to Fig. 25, for oil gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1100 Oil Pressure Gauge: Testing and Inspection Needle Overshoots Gauge Fig. 26 Oil Gauge Diagnosis: Needle Overshoots Range Refer to Fig. 26, for oil gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation Oil Pressure Warning Lamp/Indicator: Technical Service Bulletins Engine Oil Pressure Gauge/Lamp - Operation BULLETIN NUMBER SB93-01-001 ISSUE DATE January 7, 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) ENGINE OIL PRESSURE AFFECTED VEHICLES 1992-93 Trooper (UX) and 1993 Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION Oil pressure gauge readings can vary greatly as oil temperature and engine speed change. A "low" gauge reading at hot idle does not necessarily indicate a lubrication system problem. This Service Bulletin describes oil pressure gauge and oil pressure warning light operation. SERVICE PROCEDURE Oil Pressure Gauge Depending on oil temperature and engine RPM, the normal oil pressure gauge reading can range from 8.5 psi at hot idle to more than 100 psi during cold acceleration (Figure 1). If the engine oil pressure is below 8.5 psi, follow the appropriate Workshop Manual instructions for diagnosis and repair procedures for the lubrication system and/or oil pressure gauge. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 1105 Oil Pressure Warning Light If engine oil pressure falls to 2.8 psi or below during engine operation, the on pressure warning light (Figure 2) will come on. Refer to the appropriate Workshop Manual for lubrication system and/or oil pressure warning light diagnosis and repair procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Page 1106 Oil Pressure Warning (Component Location Index) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure: .................................................................................................................................................. 392 550 kPa (56.9 - 80.4 psi) at 3000 rpm. (Normal operating temperature of about 80°C (176°F).) 1992-93 Oil pressure: ................................................................................................................................................ more than 59 kPa (0.6 kg/cm2 (9 psi) at idle. 3,200 rpm, ................................................................................................................................................... 363 451 kPa (3.7 - 4.6 kg/cm2 (53-65 psi) at (Normal operating temperature of about 80°C (176°F).) 1994-95 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1111 Engine Oil Pressure: Testing and Inspection 1. Check for dirt, gasoline or water in the engine oil. a. Change the oil if dirt, gasoline, or water are present. b. Check the viscosity of the oil. c. Change the oil if the viscosity is outside the specified standard. d. Refer to the Engine Lubrication. 2. Check the engine oil level. - The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. - If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit. 4. Install an oil pressure gage. 5. Start the engine and allow the engine to reach normal operating temperature about 80°C (176°F). 6. Measure the oil pressure. Oil pressure should be: 392 - 550 kPa (56.9 - 80.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the oil pressure gage. 9. Install the oil pressure unit. 10. Start the engine and check for leaks. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair Technical Service Bulletin # 9301002 Date: 930201 Campaign - 93S921 Engine Oil Pump Repair BULLETIN NUMBER SB93-01-002 ISSUE DATE February 1993 GROUP ENGINE TROOPER (UX) RODEO (UC) ENGINE OIL PUMP CAMPAIGN Campaign ID and Part Information CAMPAIGN IDENTIFICATION NUMBER Number 93S-921 has been assigned to this campaign. This number will appear on all communications and documentation of any nature dealing with this campaign. AFFECTED VEHICLES 1992-93 Trooper (UX) and Rodeo (UC) 3.2L V6 models within the following VIN ranges, within engine serial number range 019634 - 037572: ^ 1992 Trooper (UX) model; within VIN range N7909583 - N7915679; ^ 1993 Trooper (UX) models within VIN range P7900015 - P7904360;* ^ 1993 Rodeo (UC) models within VIN range P4300059 - P4303383 * and P4303589. * Except VINs listed in Attachment A. SERVICE INFORMATION On affected vehicles, the oil pressure relief valve in the oil pump may stick, causing the oil filter to deform and leak oil. Installing a new, improved relief valve and spring in the oil pump as described in this Campaign Bulletin will eliminate this condition. DEALER RESPONSIBILITY Isuzu dealers are responsible for repairing any affected vehicle at no charge to owners, regardless of date of purchase, mileage or selling dealer. Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a dealership for service, the dealer must take the necessary steps to ensure this campaign correction has been made before selling or releasing the vehicle. Each Isuzu dealer will be supplied a copy of the AIMI Campaign Report (AWS 123-1A), listing affected vehicles assigned to that dealership. The Report contains VIN and detailed owner information. If none of the affected vehicles were assigned to a dealership, no Report will be sent. PARTS INFORMATION The oil pump repair kit and campaign label listed have been sent automatically to each dealer. The quantity of parts shipped is dependent upon the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1120 dealer's sales volume of affected vehicles. NOTE: O-ring replacement is not normally required unless damaged during removal. Service Procedure 1. Disconnect the negative battery cable. 2. Raise the vehicle on a hoist. 3. Drain the engine oil. Remove and discard the oil filter. 4. 4WD ONLY: Remove the engine skidplate. Remove the exhaust and transfer protectors. See Figure 1. 5. Remove the suspension crossmember (Figure 2). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1121 6. RODEO 4WD ONLY. (Figure 3): ^ a. Remove the radiator skidplate. ^ b. Remove 4 stabilizer bar-to-frame retaining bolts. ^ c. Remove 2 stabilizer bar-to-lower control arm retaining nuts (with 1 washer and bushing each). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1122 7. Remove the pitman arm (Figure 4) from the steering box, using special tool J-29107. 8. Remove relay lever (idler arm) assembly from the frame (4 bolts). See Figure 4. 9. 4WD ONLY: Support the front axle with jacks. Remove the axle breather hose. Remove the 2 nuts and bolts from the front axle case bracket on both sides (Figure 5) 10. 4WD ONLY: Lower the front axle assembly until it rests on the lower control arms. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1123 11. Remove the wiring harness heat protector (Figure 6), located beside the oil pan. 12. Remove the starter (Figure 6). 13. On automatic transmission models only (Fig. 7) a. Remove the starter harness bracket fixing bolts and move the electrical harnesses away from the oil pan. b. Remove the flywheel dust covered oil cooler pipe clamp brackets located at the stiffener. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1124 14. Remove the stiffener (Figure 8). 15. Remove the oil pan, using scaler cutter J-37218. Use care to prevent damaging the oil pan during removal. 16. Remove the oil pipe, two O-rings, cap and spring, from the oil pump. Discard spring. Do not discard the O-rings unless they are damaged. See Figure 9. 17. Remove and discard the oil pump relief valve. If it is stuck, use a 12 mm tap to remove. 18. Apply a coating of engine oil to the entire surface of the new relief valve provided in the repair kit, then install the valve into the pump. IMPORTANT The relief valve must be installed in the proper direction, as shown in Figure 9. 19. Apply a coating of engine oil to the new spring provided in the repair kit, then install the spring. 20. Reinstall the oil pump cap and torque to 69 in.lbs. 21. Reinstall the O-rings (replace with new parts if original O-rings were damaged) and oil pipe. Torque to 7 ft.lbs. 22. Remove residual sealant, lubricant and moisture from the oil pan and engine block mounting surface, then dry thoroughly. Apply a bead of silicone gasket sealant TB1207B (listed in "Parts Information" section of this Campaign Bulletin) to the mounting surface of the oil pan. Reinstall the oil pan and torque the fixing bolts to 87 in.lbs. 23. Automatic transmission models only: a. Reinstall the oil cooler pipe clamp brackets and flywheel dust cover. Torque the flywheel dust cover bolts to 52 in.lbs. b. Reinstall the harness Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1125 24. Reinstall the stiffener and torque to 35 ft.lbs. 25. Reinstall the starter and torque the fixing bolts to 30 ft.lbs. 26. Reinstall the heat protector and torque the fixing bolts to 52 in.lbs. 27. 4WD ONLY: Reinstall the front axle. Torque the fixing bolts to 112 ft.lbs. 28. Reinstall the relay lever (idler arm) assembly to the frame. Torque the 4 fixing nuts to 33 ft.lbs. 29. Reinstall the pitman arm. Torque the fixing nut to 160 ft.lbs. 30. RODEO 4WD ONLY ^ a. Reinstall the stabilizer bar-to-frame retaining bolts. Torque bolts to 21 ft.lbs. ^ b. Reinstall stabilizer bar-to-lower control arm retaining bolts with washers and bushings. Torque nuts to 8 ft.lbs. ^ c. Reinstall radiator skidplate. 31. Reinstall the suspension crossmember. Torque the fixing bolts to 58 ft.lbs. 32. 4WD ONLY: Reinstall the exhaust and transfer protectors. Torque the fixing bolts to 27 ft.lbs. 33. 4WD ONLY: Reinstall the engine skidplate. 34. Install a new oil filter. 35. Replenish the engine oil and check oil level with dipstick. 36. Reconnect the negative battery cable. 37. Start the engine and allow to idle for one minute. Increase engine speed to 3,000 rpm momentarily and verily proper oil pump relief valve operation by observing that the oil pressure gauge reading varies with rpm. Check for oil leaks. 38. Road test the vehicle to verify proper steering operation. 39. Affix a campaign label to the inside of the driver's door. Using a ball-point pen, fill in label with Campaign Number 93S-921 and Isuzu dealer code. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1126 Owner Letter Dear Isuzu Trooper or Rodeo Owner: Through our continuing effort to assure maximum customer satisfaction with our product Isuzu Motors Limited has determined that a condition affecting the operation of the engine oil pump may exist in certain 1992-93 Isuzu Trooper and 1993 Rodeo vehicles with 3.2 liter engine (SOHC and DOHC versions). WHAT IS THE DEFECT? In cooler ambient climates, the pressure regulator valve in the oil pump may stick, creating excessive oil pressure while causing the oil filter to deform and leak oil. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1127 WHAT YOU SHOULD DO At your earliest convenience, please make an appointment with your authorized Isuzu Dealer, who will repair the oil pump. It will take approximately one day, and will be performed free of charge. Please ask your Dealer if additional time will be needed to schedule and/or repair your vehicle. Have your Dealer refer to Campaign Bulletin SB93-01-002. If you believe the condition has not been or cannot be remedied without charge within a reasonable time which is no longer than 60 days from the date you take the vehicle to the Isuzu Dealer for remedy of the condition), you may contact the appropriate Isuzu Regional Office listed in the back of the Owner's Manual, or the National Customer Relations Office, American Isuzu Motors Inc., P.O. Box 2480, City of Industry, CA 91714-5007 (phone 800-255-6727). Because of our desire to assure trouble-free operation of your Isuzu vehicle, we appreciate your cooperation in having this correction completed as soon as possible. We are indeed sorry for any inconvenience this may have caused and welcome any comments or suggestions regarding the completion of this repair. Thank you for your prompt attention to this matter, thus affording us the opportunity to be of service to a valued Isuzu Customer. IMPORTANT: If you have sold or traded your Isuzu vehicle, please enter the owner's name and address, if known on the enclosed "Change of Information" postcard and drop it in the mail. Postage has already been paid. We will contact the new owner. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair Technical Service Bulletin # 9301002 Date: 930201 Campaign - 93S921 Engine Oil Pump Repair BULLETIN NUMBER SB93-01-002 ISSUE DATE February 1993 GROUP ENGINE TROOPER (UX) RODEO (UC) ENGINE OIL PUMP CAMPAIGN Campaign ID and Part Information CAMPAIGN IDENTIFICATION NUMBER Number 93S-921 has been assigned to this campaign. This number will appear on all communications and documentation of any nature dealing with this campaign. AFFECTED VEHICLES 1992-93 Trooper (UX) and Rodeo (UC) 3.2L V6 models within the following VIN ranges, within engine serial number range 019634 - 037572: ^ 1992 Trooper (UX) model; within VIN range N7909583 - N7915679; ^ 1993 Trooper (UX) models within VIN range P7900015 - P7904360;* ^ 1993 Rodeo (UC) models within VIN range P4300059 - P4303383 * and P4303589. * Except VINs listed in Attachment A. SERVICE INFORMATION On affected vehicles, the oil pressure relief valve in the oil pump may stick, causing the oil filter to deform and leak oil. Installing a new, improved relief valve and spring in the oil pump as described in this Campaign Bulletin will eliminate this condition. DEALER RESPONSIBILITY Isuzu dealers are responsible for repairing any affected vehicle at no charge to owners, regardless of date of purchase, mileage or selling dealer. Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a dealership for service, the dealer must take the necessary steps to ensure this campaign correction has been made before selling or releasing the vehicle. Each Isuzu dealer will be supplied a copy of the AIMI Campaign Report (AWS 123-1A), listing affected vehicles assigned to that dealership. The Report contains VIN and detailed owner information. If none of the affected vehicles were assigned to a dealership, no Report will be sent. PARTS INFORMATION The oil pump repair kit and campaign label listed have been sent automatically to each dealer. The quantity of parts shipped is dependent upon the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1133 dealer's sales volume of affected vehicles. NOTE: O-ring replacement is not normally required unless damaged during removal. Service Procedure 1. Disconnect the negative battery cable. 2. Raise the vehicle on a hoist. 3. Drain the engine oil. Remove and discard the oil filter. 4. 4WD ONLY: Remove the engine skidplate. Remove the exhaust and transfer protectors. See Figure 1. 5. Remove the suspension crossmember (Figure 2). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1134 6. RODEO 4WD ONLY. (Figure 3): ^ a. Remove the radiator skidplate. ^ b. Remove 4 stabilizer bar-to-frame retaining bolts. ^ c. Remove 2 stabilizer bar-to-lower control arm retaining nuts (with 1 washer and bushing each). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1135 7. Remove the pitman arm (Figure 4) from the steering box, using special tool J-29107. 8. Remove relay lever (idler arm) assembly from the frame (4 bolts). See Figure 4. 9. 4WD ONLY: Support the front axle with jacks. Remove the axle breather hose. Remove the 2 nuts and bolts from the front axle case bracket on both sides (Figure 5) 10. 4WD ONLY: Lower the front axle assembly until it rests on the lower control arms. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1136 11. Remove the wiring harness heat protector (Figure 6), located beside the oil pan. 12. Remove the starter (Figure 6). 13. On automatic transmission models only (Fig. 7) a. Remove the starter harness bracket fixing bolts and move the electrical harnesses away from the oil pan. b. Remove the flywheel dust covered oil cooler pipe clamp brackets located at the stiffener. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1137 14. Remove the stiffener (Figure 8). 15. Remove the oil pan, using scaler cutter J-37218. Use care to prevent damaging the oil pan during removal. 16. Remove the oil pipe, two O-rings, cap and spring, from the oil pump. Discard spring. Do not discard the O-rings unless they are damaged. See Figure 9. 17. Remove and discard the oil pump relief valve. If it is stuck, use a 12 mm tap to remove. 18. Apply a coating of engine oil to the entire surface of the new relief valve provided in the repair kit, then install the valve into the pump. IMPORTANT The relief valve must be installed in the proper direction, as shown in Figure 9. 19. Apply a coating of engine oil to the new spring provided in the repair kit, then install the spring. 20. Reinstall the oil pump cap and torque to 69 in.lbs. 21. Reinstall the O-rings (replace with new parts if original O-rings were damaged) and oil pipe. Torque to 7 ft.lbs. 22. Remove residual sealant, lubricant and moisture from the oil pan and engine block mounting surface, then dry thoroughly. Apply a bead of silicone gasket sealant TB1207B (listed in "Parts Information" section of this Campaign Bulletin) to the mounting surface of the oil pan. Reinstall the oil pan and torque the fixing bolts to 87 in.lbs. 23. Automatic transmission models only: a. Reinstall the oil cooler pipe clamp brackets and flywheel dust cover. Torque the flywheel dust cover bolts to 52 in.lbs. b. Reinstall the harness Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1138 24. Reinstall the stiffener and torque to 35 ft.lbs. 25. Reinstall the starter and torque the fixing bolts to 30 ft.lbs. 26. Reinstall the heat protector and torque the fixing bolts to 52 in.lbs. 27. 4WD ONLY: Reinstall the front axle. Torque the fixing bolts to 112 ft.lbs. 28. Reinstall the relay lever (idler arm) assembly to the frame. Torque the 4 fixing nuts to 33 ft.lbs. 29. Reinstall the pitman arm. Torque the fixing nut to 160 ft.lbs. 30. RODEO 4WD ONLY ^ a. Reinstall the stabilizer bar-to-frame retaining bolts. Torque bolts to 21 ft.lbs. ^ b. Reinstall stabilizer bar-to-lower control arm retaining bolts with washers and bushings. Torque nuts to 8 ft.lbs. ^ c. Reinstall radiator skidplate. 31. Reinstall the suspension crossmember. Torque the fixing bolts to 58 ft.lbs. 32. 4WD ONLY: Reinstall the exhaust and transfer protectors. Torque the fixing bolts to 27 ft.lbs. 33. 4WD ONLY: Reinstall the engine skidplate. 34. Install a new oil filter. 35. Replenish the engine oil and check oil level with dipstick. 36. Reconnect the negative battery cable. 37. Start the engine and allow to idle for one minute. Increase engine speed to 3,000 rpm momentarily and verily proper oil pump relief valve operation by observing that the oil pressure gauge reading varies with rpm. Check for oil leaks. 38. Road test the vehicle to verify proper steering operation. 39. Affix a campaign label to the inside of the driver's door. Using a ball-point pen, fill in label with Campaign Number 93S-921 and Isuzu dealer code. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1139 Owner Letter Dear Isuzu Trooper or Rodeo Owner: Through our continuing effort to assure maximum customer satisfaction with our product Isuzu Motors Limited has determined that a condition affecting the operation of the engine oil pump may exist in certain 1992-93 Isuzu Trooper and 1993 Rodeo vehicles with 3.2 liter engine (SOHC and DOHC versions). WHAT IS THE DEFECT? In cooler ambient climates, the pressure regulator valve in the oil pump may stick, creating excessive oil pressure while causing the oil filter to deform and leak oil. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Technical Service Bulletins > Recalls for Oil Pressure Regulator Valve: > 9301002 > Feb > 93 > Campaign - 93S921 Engine Oil Pump Repair > Page 1140 WHAT YOU SHOULD DO At your earliest convenience, please make an appointment with your authorized Isuzu Dealer, who will repair the oil pump. It will take approximately one day, and will be performed free of charge. Please ask your Dealer if additional time will be needed to schedule and/or repair your vehicle. Have your Dealer refer to Campaign Bulletin SB93-01-002. If you believe the condition has not been or cannot be remedied without charge within a reasonable time which is no longer than 60 days from the date you take the vehicle to the Isuzu Dealer for remedy of the condition), you may contact the appropriate Isuzu Regional Office listed in the back of the Owner's Manual, or the National Customer Relations Office, American Isuzu Motors Inc., P.O. Box 2480, City of Industry, CA 91714-5007 (phone 800-255-6727). Because of our desire to assure trouble-free operation of your Isuzu vehicle, we appreciate your cooperation in having this correction completed as soon as possible. We are indeed sorry for any inconvenience this may have caused and welcome any comments or suggestions regarding the completion of this repair. Thank you for your prompt attention to this matter, thus affording us the opportunity to be of service to a valued Isuzu Customer. IMPORTANT: If you have sold or traded your Isuzu vehicle, please enter the owner's name and address, if known on the enclosed "Change of Information" postcard and drop it in the mail. Postage has already been paid. We will contact the new owner. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Description and Operation Intake Manifold: Description and Operation Intake Manifold PURPOSE Routes intake air from the common chamber to the intake ports on the cylinder head. LOCATION On top of the engine. CONSTRUCTION It is a sealed cast aluminum component. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Service and Repair Intake Manifold: Service and Repair Intake Manifold Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Relieve fuel system pressure as outlined under Precautions. 3. Disconnect battery ground cable, then insulate cable end with electrical tape, or equivalent. 4. Remove air cleaner assembly from engine compartment. 5. Disconnect vacuum hose from evaporation canister, then air vacuum hoses from throttle valve and common chamber. 6. Disconnect electrical connectors from MAP sensor, EGR VSV, MAT sensor and ground cable. 7. Disconnect spark plug wires from cylinder head covers, then three DIS module electrical connectors. 8. Remove throttle body, then the EGR valve. 9. Remove common chamber, then disconnect fuel supply and return hoses from fuel rail. 10. Disconnect electrical connectors from fuel injectors, then thermo sensor connector. 11. Remove intake manifold. 12. Reverse procedure to install. 13. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Service and Repair > Page 1146 Intake Manifold: Service and Repair Common Chamber Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Relieve fuel system pressure as outlined under Precautions. 3. Disconnect battery ground cable, then insulate cable end with electrical tape, or equivalent. 4. Remove air cleaner assembly, then disconnect accelerator cable from throttle body and cable bracket. 5. Mark vacuum line positions on common chamber, then disconnect hoses from common chamber. 6. Disconnect spark plug wires from valve covers, then three electrical connectors from DIS module. 7. Remove DIS module and spark plug wires from engine as an assembly. 8. Remove throttle body, then EGR valve assembly. 9. Remove common chamber from engine. 10. Reverse procedure to install. 11. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation Oil Pressure Gauge: Technical Service Bulletins Engine Oil Pressure Gauge/Lamp - Operation BULLETIN NUMBER SB93-01-001 ISSUE DATE January 7, 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) ENGINE OIL PRESSURE AFFECTED VEHICLES 1992-93 Trooper (UX) and 1993 Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION Oil pressure gauge readings can vary greatly as oil temperature and engine speed change. A "low" gauge reading at hot idle does not necessarily indicate a lubrication system problem. This Service Bulletin describes oil pressure gauge and oil pressure warning light operation. SERVICE PROCEDURE Oil Pressure Gauge Depending on oil temperature and engine RPM, the normal oil pressure gauge reading can range from 8.5 psi at hot idle to more than 100 psi during cold acceleration (Figure 1). If the engine oil pressure is below 8.5 psi, follow the appropriate Workshop Manual instructions for diagnosis and repair procedures for the lubrication system and/or oil pressure gauge. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 1152 Oil Pressure Warning Light If engine oil pressure falls to 2.8 psi or below during engine operation, the on pressure warning light (Figure 2) will come on. Refer to the appropriate Workshop Manual for lubrication system and/or oil pressure warning light diagnosis and repair procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Circuit Schematics CIRCUIT APPLICATION Circuit schematics break the entire electrical system into individual circuits. Electrical components that work together are shown together. CURRENT FLOW Each drawing is arranged so current flows from positive, at top of page to ground, at bottom. The "hot" labels at the top of a fuse indicate when the ignition switch supplies power to that fuse. CIRCUIT NETWORKING Wires that connect to another circuit are shown with an arrowhead pointing in the direction of current flow. The name of the circuit that shares the wiring is shown for reference. POWER AND GROUND SUPPLY "See Fuse Box Details" indicates there are connections to other circuits that are not shown. All shared circuits are shown on the Fuse Box Details schematic. "See Ground Distribution" indicates there are shared ground circuits which are shown on the ground distribution schematic. CIRCUIT/COMPONENT LOCATION No attempt is made to represent the location or proximity of components. If a wire is actually 4 foot or 4 inches, it will be represented without regard in the schematic. Component/Connector Location and I.D. COMPONENT AND CONNECTOR LOCATION Supplied with the wiring schematic is a component location index. The index lists the correct photograph for the components and connectors listed. The photographs are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. HARNESS ROUTING Harness routing and selected connectors related to the system are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. CONNECTOR I.D. All connectors with more than 2 terminals are illustrated in this section. The connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION. Fuse Box Details The fuse box details schematic shows all the wiring between a fuse and the components connected to the output side of the fuse. It shows what supplies power to the fuse and when it is energized. Ground Distribution The ground distribution schematics show which components share a common ground point. This information can be very helpful in diagnosing inoperative circuits. If more than one components are not working and they share a common ground, it is likely the ground circuit is faulty. However, if one of the circuits is operative and the other is not, you know the ground and the wire are good up to a splice. Light Switch Details The light switch details schematic shows all the wiring between the light switch/relays and the components connected to the output side of the light switch/relays. Power Distribution The Power distribution schematic shows the wiring from the battery and alternator to the: - Starter solenoid - Fuse box - Light switch - Ignition switch - Fuse link The first component after a fuse link is shown. In certain instances, the first component after a fuse box, fuse and light switch is shown. All fuses in the schematic are "Hot At All Times", since battery voltage is the direct source. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 Symbol Identification Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Symbol Identification Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Clear: CLR Gray: GRY Green: GRN Light Blue: LT BLU Light Green: LT GRN Orange: ORN Pink: PNK Red: RED Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 White: WHT Yellow: YEL Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Oil Pressure Gauge: Diagnostic Aids Continuity and Resistance Check Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Disconnect the battery or connector so there is no power between the check points. 3. Set the ohmmeter to the appropriate range. Continuity And Resistance Check 4. Connect the two leads of the meter to each of the check points. Diode Check 5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity. b. When connecting the two leads in reverse, there should not be continuity. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Electronic Component Handling STATIC DISCHARGE ^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. ^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board. TESTING ^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. ^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE ^ Do not try to disassemble the control unit. ^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and radio. ^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's. ^ Avoid getting water on any of the Fuel and Engine Control System Components. ^ Never apply battery power to a component unless directed to do so in a test procedure. Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Battery Precautions CAUTION: Never use a booster/starter which has a voltage rating above 12 volts to start engine. - Always ensure the battery is properly connected to the vehicle prior to attempting to start engine. - Don't disconnect the battery when the engine is running. - When charging a battery, be sure battery cables are disconnected. - The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery. Electrical Connections and Circuits 1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling. 2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure. 3. Do not use a self powered test lamp to check continuity. 4. Do not create any arcing to check the continuity of a circuit. Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 testing electronic components. Proper Tools and Testing Procedures DIGITAL VOLT/OHM METER Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components, unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU circuits and components. TESTING PROCEDURES Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or applying battery power to these circuits could damage the ECU and cause a system failure. Finding Short Circuits Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. 2. Remove the blown fuse and disconnect all loads for that circuit. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 Finding A Short Circuit 3. Connect a test lamp in place of the fuse. 4. Establish conditions that turn the test lamp on. EXAMPLE a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect the relay) 5. Connect and disconnect the components or connectors in the circuit while watching the test light. a) The test light will come on when the shorted circuit or component is connected. b) The test light will go off when the circuit or component is disconnected Voltage Check Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 Meter Types 1. Use a digital or analog multimeter with a minimum 10k ohm resistance. Voltage Check 2. Establish conditions in which voltage should be present at the check point. EXAMPLE: a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF) 3. Set the volt meter to the appropriate range for the circuit being tested. 4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or component terminal. NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 Circuit Protection Devices PURPOSE The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. CIRCUIT PROTECTION DEVICES There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. CIRCUIT BREAKERS A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in this vehicle: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until the condition causing the high current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fig. 1 Fuse Devices Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 Fig. 2 Fuse Rating and Color FUSES The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 wiring from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by Maxifuses in future vehicles. Fig. 3 Good and Damaged Fusible Links Fig. 6 Wire Size Conversion Table FUSIBLE LINKS In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig. 3. Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links: ^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all the way through. ^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. ^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 Fig. 4 Single Wire Feed Fusible Link Fig. 5 Double Wire Feed Fusible Link SERVICE PROCEDURE - To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp and Seal splices whenever possible. - To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire, Fig. 5. Typical Electrical Repair An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION - Locate the damaged wire. - Find and correct the cause of the wire insulation damage. - For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing procedure). Splicing Copper Wire Using Splice Clips The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices, harness branches or connectors. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Fig. 8 Crimping the Splice Clip Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 Fig. 9 Completing the Crimp Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose, and - No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9. Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the manufacturer's instruction for the solder equipment you are using. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 Fig. 11 Proper First Taping Fig. 12 Proper Second Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig. 12. Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used where there are special requirements such as moisture scaling. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one to one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Fig. 6 Wire Size Conversion Table Step 3: Strip the Insulation Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Fig. 13 Hand Crimp Tool Fig. 14 Seal Splice Sequence Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation around the Splice Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved, Fig. 14. Splicing Twisted/Shielded Cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 Fig. 15 Twisted/Shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. Fig. 16 The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16. Fig. 17 The Re-assembled Cable Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig. 17. Fig. 18 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair. Repairing Connectors The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather Pack. ^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced. ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 Figure 1 - Typical Push-To-Seat Connector Fig. 20 Typical Pull-to-Seat Connector and Terminal PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. 1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated. 2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. 3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. 4. Separate the connector halves and back out seals. 5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 6. Locate the terminal lock tang in the connector canal. 7. Insert the proper size pick straight into the connector canal at the mating end of the connector. 8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: Never use force to remove a terminal from a connector. 9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. 11. Install any CPAs or TPAs, close any secondary locks and join connector halves. Fig. 21 Typical Weather Pack Connector and Terminal Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 WEATHER PACK Follow the steps below to repair Weather Pack(R) connectors, Fig. 21. 1. Separate the connector halves. 2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. 3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. 5. Gently pull on the lead to remove the terminal through the back of the connector. NOTE: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR. 7. Reform the lock tang and reseat terminal in connector body. 8. Close secondary locks and join connector halves. Terminal Repair Fig. 22 Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.) 1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. 2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). 3. Remove insulation. 4. Align seal with end of cable insulation (Weather Pack(R) terminals only). 5. Position strip (and seal for Weather Pack(R)) in terminal. 6. Hand crimp core wings. 7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). 8. Solder all hand crimped terminals. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Oil Pressure Warning Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Needle Does Not Move Oil Pressure Gauge: Testing and Inspection Needle Does Not Move Fig. 24 Oil Gauge Diagnosis: Needle Does Not Move Refer to Fig. 24, for oil gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1178 Oil Pressure Gauge: Testing and Inspection Gauge Reading Is Too Low Fig. 25 Oil Gauge Diagnosis: Reading Is Too Low Refer to Fig. 25, for oil gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1179 Oil Pressure Gauge: Testing and Inspection Needle Overshoots Gauge Fig. 26 Oil Gauge Diagnosis: Needle Overshoots Range Refer to Fig. 26, for oil gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation Oil Pressure Warning Lamp/Indicator: Technical Service Bulletins Engine Oil Pressure Gauge/Lamp - Operation BULLETIN NUMBER SB93-01-001 ISSUE DATE January 7, 1993 GROUP ENGINE TROOPER (UX) AND RODEO (UC) ENGINE OIL PRESSURE AFFECTED VEHICLES 1992-93 Trooper (UX) and 1993 Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION Oil pressure gauge readings can vary greatly as oil temperature and engine speed change. A "low" gauge reading at hot idle does not necessarily indicate a lubrication system problem. This Service Bulletin describes oil pressure gauge and oil pressure warning light operation. SERVICE PROCEDURE Oil Pressure Gauge Depending on oil temperature and engine RPM, the normal oil pressure gauge reading can range from 8.5 psi at hot idle to more than 100 psi during cold acceleration (Figure 1). If the engine oil pressure is below 8.5 psi, follow the appropriate Workshop Manual instructions for diagnosis and repair procedures for the lubrication system and/or oil pressure gauge. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 1184 Oil Pressure Warning Light If engine oil pressure falls to 2.8 psi or below during engine operation, the on pressure warning light (Figure 2) will come on. Refer to the appropriate Workshop Manual for lubrication system and/or oil pressure warning light diagnosis and repair procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Page 1185 Oil Pressure Warning (Component Location Index) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug Technical Service Bulletin # SB9401002 Date: 940701 Campaign - Oil Leak From Camshaft End Plug BULLETIN NUMBER SB94-01-002 ISSUE DATE JULY 1994 GROUP ENGINE TROOPER (UX) AND RODEO (UC) CAMSHAFT END PLUG RETAINING PLATE CAMPAIGN BULLETIN CAMPAIGN IDENTIFICATION NUMBER Number 94V-094 has been assigned to this campaign. This number will appear on all communications and documentation of any nature dealing with the campaign. SERVICE INFORMATION Condition: Certain 1992-94 Trooper models with 3.2L 6VD1 engines (SOHC and DOHC versions) and 1993-94 Rodeo models with 3.2L 6VD1 SOHC engines, may expenence dislodging of the camshaft end plug(s) from the cylinder heads causing rapid oil loss. Continued operation of the engine could result in engine damage, and in the worst case, an engine compartment fire from oil spilling on the exhaust system. AFFECTED VEHICLES Possible Cause: Analysis indicates that this condition is most likely to occur in cold weather climate and is attributable to the constant expansion and contraction of the cylinder head metal, which causes the camshaft end plug(s) to become dislodged from the cylinder head. Correction: To correct this condition, dealers will install a camshaft end plug retaining plate kit on all affected vehicles. When installed, as described in this Campaign Bulletin, these parts will provide the necessary support to keep the camshaft end plugs from dislodging and thus prevent any rapid oil loss, potential engine damage, and fluid ignition. DEALER RESPONSIBILITY Isuzu Dealers are required to service all eligible vehicles at no charge to the owner, regardless of mileage, age of vehicle, or ownership. Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a dealership for service, the dealer must take the necessary steps to ensure that this campaign correction has been made before selling or releasing the vehicle. Each Isuzu Dealer will be supplied a copy of the AIMI Campaign Report (AWS 123-1A) listing affected vehicles assigned to that dealership. The report contains VIN and detailed owner information obtained from state motor vehicle registration records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, dealers are urged to limit the use of this listing to the follow-up necessary to complete this campaign. If none of the affected vehicles are assigned to a dealership, no campaign report will be sent. OWNER NOTIFICATION American Isuzu Motors Inc. will notify owners of affected vehicles already retailed by letter (see enclosed copy). Dealers should follow up with vehicle Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1195 owners by sending a Campaign Reminder Notice (AIMI SVCF-1052) to all vehicle owners listed in the AIMI Campaign Report AWS 123-1A. These postcards can be obtained from any regional office. PARTS INFORMATION The parts listed have been shipped automatically to each dealer. The quantity of parts shipped is dependent upon the dealer's sales volume of affected vehicles. These parts are also available from American Isuzu Parts Distribution Network (AIPDN). FLAT RATE MANUAL UPDATE INFORMATION Use the new labor operations as shown. Use Trouble Code 07 for all campaign operations. Labor time includes 0.1 administration allowance. Service Procedure 3.2L 6VD1-V SOHC Engine (1992-94 Trooper and 1993-1994 Rodeo) ^ Right-Hand - Rear Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1196 1. Remove the two cylinder head cover bolts (6 mm) (Figure 1). 2. Position the retaining plate over the camshaft end plug and secure the plate by reinstalling the two cylinder head cover bolts. Tighten the two bolts to 65 in.-lb. ^ Left-Hand - Rear 1. Remove the air cleaner cover. CAUTION: The Exhaust Gas Recirculation (EGR) pipe generates high surface temperatures that can cause severe burns. Make certain that the EGR pipe is cool to the touch when working in its vicinity. 2. Thread the two kit bolts (8 mm) into the rear of the cylinder head (Figure 1). 3. Position the retaining plate over the camshaft end plug and secure the plate by tightening the two kit bolts to 191 in.-lb. 4. Reinstall the air cleaner cover. 5. Affix the Recall Campaign Label adjacent to the manufacturer's identification label located inside the driver's door. Using a ball-point pen, fill in the label with Campaign Number 94V-094, the Isuzu dealer code, and the repair date. 3.2L 6VD1-W DOHC Engine (1992-1994 Trooper Only) ^ Right-Hand - Rear Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1197 1. Remove the right-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the ground wire washer. 2. Position the retaining plate over the camshaft end plugs and secure the plate using the ground wire eyelet/bolt and kit bolt (6 mm). Tighten the two bolts to 70 in. lb. ^ Right-Hand - Front 1. Disconnect the negative battery harness clip (at the fuel line bracket.) 2. Remove the fuel line bracket bolt for better access to the cylinder head cover bolts. 3. Remove the two cylinder head cover bolts (6 mm) (Figure 2). 4. Position the retaining plate over the camshaft end plugs and secure the plate by reinstalling the two cylinder head cover bolts. Tighten the two bolts to 65 in.-lb. 5. Reinstall the fuel line bracket bolt and reconnect the negative battery harness clip. ^ Left-Hand - Front 1. Remove the air cleaner cover. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1198 2. Remove the two cylinder head cover bolts (6mm) (Figure 2). 3. Position the retaining plate over the camshaft end plugs and secure the plate by reinstalling the two cylinder head cover bolts. Tighten the two bolts to 65 in.-lb. ^ Left-Hand - Rear CAUTION: The Exhaust Gas Recirculation (EGR) pipe generates high surface temperatures that can cause severe burns. Make certain that the EGR pipe is cool to the touch when working in its vicinity. 1. Remove the left-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the ground wire washer. 2. Position the retaining plate over the camshaft end plugs and secure the plate using the ground wire eyelet (bolt and kit bolt (6 mm). Tighten the two bolts to 70 in.lb. 3. Reinstall the air cleaner cover. 4. Affix the Recall Campaign Label adjacent to the manufacturer's identification label located inside the driver's door. Using a ball-point pen, fill in the label with Campaign Number 94V-094, the Isuzu dealer Code and the repair date. Owner Letter July 1994 Dear Isuzu Rodeo or Trooper Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Isuzu Motors Limited has determined that a defect which relates to motor vehicle safety exists in all 1992-1993 and certain 1994 Isuzu Rodeo and Trooper vehicles with the 3.2 liter engine. WHAT IS THE DEFECT? These vehicles may exhibit a condition in which the camshaft seal end plug may become dislodged from the cylinder head due to constant expansion and contraction of the cylinder head in cold weather climates causing rapid oil loss. Continued operation of the engine could result in engine damage, and in the worst case, an engine compartment fire from oil spilling on the exhaust system. WHAT WE WILL DO? To correct this condition, your dealer will install a camshaft plug retaining plate. This service will be performed for you at no charge. WHAT YOU SHOULD DO? Please contact your local Isuzu dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle. Presentation of this letter to your dealer will assist in making the necessary correction in the shortest possible time. Please have your dealer refer to Campaign Bulletin SB94-O1-0o2. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. Your Isuzu dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed serviced date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the appropriate Isuzu Regional office listed in the back of the Owner's Manual or the National Customer Relations Office, American Isuzu Motors Inc., P.O. Box 2480, City of Industry, CA 91746-0480, or call 1-800-255-6727. After contacting your dealer or Regional Office or National Office, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street S.W., Washington, D.C. 20590; or call 1-800-424-9393 (Washington D.C. residents can call 366-0123). We are sorry to cause you this inconvenience; however, in the interest of your safety, it is very important that your vehicle be returned to your Isuzu dealer as soon as possible for repair. IMPORTANT: If you have sold or traded your Isuzu vehicle, please enter the owners name and address, if known, on the enclosed "Change of information" postcard and drop it in the mail. Postage has already been paid. We will contact the new owner. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Recalls for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug Technical Service Bulletin # SB9401002 Date: 940701 Campaign - Oil Leak From Camshaft End Plug BULLETIN NUMBER SB94-01-002 ISSUE DATE JULY 1994 GROUP ENGINE TROOPER (UX) AND RODEO (UC) CAMSHAFT END PLUG RETAINING PLATE CAMPAIGN BULLETIN CAMPAIGN IDENTIFICATION NUMBER Number 94V-094 has been assigned to this campaign. This number will appear on all communications and documentation of any nature dealing with the campaign. SERVICE INFORMATION Condition: Certain 1992-94 Trooper models with 3.2L 6VD1 engines (SOHC and DOHC versions) and 1993-94 Rodeo models with 3.2L 6VD1 SOHC engines, may expenence dislodging of the camshaft end plug(s) from the cylinder heads causing rapid oil loss. Continued operation of the engine could result in engine damage, and in the worst case, an engine compartment fire from oil spilling on the exhaust system. AFFECTED VEHICLES Possible Cause: Analysis indicates that this condition is most likely to occur in cold weather climate and is attributable to the constant expansion and contraction of the cylinder head metal, which causes the camshaft end plug(s) to become dislodged from the cylinder head. Correction: To correct this condition, dealers will install a camshaft end plug retaining plate kit on all affected vehicles. When installed, as described in this Campaign Bulletin, these parts will provide the necessary support to keep the camshaft end plugs from dislodging and thus prevent any rapid oil loss, potential engine damage, and fluid ignition. DEALER RESPONSIBILITY Isuzu Dealers are required to service all eligible vehicles at no charge to the owner, regardless of mileage, age of vehicle, or ownership. Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a dealership for service, the dealer must take the necessary steps to ensure that this campaign correction has been made before selling or releasing the vehicle. Each Isuzu Dealer will be supplied a copy of the AIMI Campaign Report (AWS 123-1A) listing affected vehicles assigned to that dealership. The report contains VIN and detailed owner information obtained from state motor vehicle registration records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, dealers are urged to limit the use of this listing to the follow-up necessary to complete this campaign. If none of the affected vehicles are assigned to a dealership, no campaign report will be sent. OWNER NOTIFICATION American Isuzu Motors Inc. will notify owners of affected vehicles already retailed by letter (see enclosed copy). Dealers should follow up with vehicle Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Recalls for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1204 owners by sending a Campaign Reminder Notice (AIMI SVCF-1052) to all vehicle owners listed in the AIMI Campaign Report AWS 123-1A. These postcards can be obtained from any regional office. PARTS INFORMATION The parts listed have been shipped automatically to each dealer. The quantity of parts shipped is dependent upon the dealer's sales volume of affected vehicles. These parts are also available from American Isuzu Parts Distribution Network (AIPDN). FLAT RATE MANUAL UPDATE INFORMATION Use the new labor operations as shown. Use Trouble Code 07 for all campaign operations. Labor time includes 0.1 administration allowance. Service Procedure 3.2L 6VD1-V SOHC Engine (1992-94 Trooper and 1993-1994 Rodeo) ^ Right-Hand - Rear Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Recalls for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1205 1. Remove the two cylinder head cover bolts (6 mm) (Figure 1). 2. Position the retaining plate over the camshaft end plug and secure the plate by reinstalling the two cylinder head cover bolts. Tighten the two bolts to 65 in.-lb. ^ Left-Hand - Rear 1. Remove the air cleaner cover. CAUTION: The Exhaust Gas Recirculation (EGR) pipe generates high surface temperatures that can cause severe burns. Make certain that the EGR pipe is cool to the touch when working in its vicinity. 2. Thread the two kit bolts (8 mm) into the rear of the cylinder head (Figure 1). 3. Position the retaining plate over the camshaft end plug and secure the plate by tightening the two kit bolts to 191 in.-lb. 4. Reinstall the air cleaner cover. 5. Affix the Recall Campaign Label adjacent to the manufacturer's identification label located inside the driver's door. Using a ball-point pen, fill in the label with Campaign Number 94V-094, the Isuzu dealer code, and the repair date. 3.2L 6VD1-W DOHC Engine (1992-1994 Trooper Only) ^ Right-Hand - Rear Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Recalls for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1206 1. Remove the right-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the ground wire washer. 2. Position the retaining plate over the camshaft end plugs and secure the plate using the ground wire eyelet/bolt and kit bolt (6 mm). Tighten the two bolts to 70 in. lb. ^ Right-Hand - Front 1. Disconnect the negative battery harness clip (at the fuel line bracket.) 2. Remove the fuel line bracket bolt for better access to the cylinder head cover bolts. 3. Remove the two cylinder head cover bolts (6 mm) (Figure 2). 4. Position the retaining plate over the camshaft end plugs and secure the plate by reinstalling the two cylinder head cover bolts. Tighten the two bolts to 65 in.-lb. 5. Reinstall the fuel line bracket bolt and reconnect the negative battery harness clip. ^ Left-Hand - Front 1. Remove the air cleaner cover. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Recalls for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1207 2. Remove the two cylinder head cover bolts (6mm) (Figure 2). 3. Position the retaining plate over the camshaft end plugs and secure the plate by reinstalling the two cylinder head cover bolts. Tighten the two bolts to 65 in.-lb. ^ Left-Hand - Rear CAUTION: The Exhaust Gas Recirculation (EGR) pipe generates high surface temperatures that can cause severe burns. Make certain that the EGR pipe is cool to the touch when working in its vicinity. 1. Remove the left-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the ground wire washer. 2. Position the retaining plate over the camshaft end plugs and secure the plate using the ground wire eyelet (bolt and kit bolt (6 mm). Tighten the two bolts to 70 in.lb. 3. Reinstall the air cleaner cover. 4. Affix the Recall Campaign Label adjacent to the manufacturer's identification label located inside the driver's door. Using a ball-point pen, fill in the label with Campaign Number 94V-094, the Isuzu dealer Code and the repair date. Owner Letter July 1994 Dear Isuzu Rodeo or Trooper Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Isuzu Motors Limited has determined that a defect which relates to motor vehicle safety exists in all 1992-1993 and certain 1994 Isuzu Rodeo and Trooper vehicles with the 3.2 liter engine. WHAT IS THE DEFECT? These vehicles may exhibit a condition in which the camshaft seal end plug may become dislodged from the cylinder head due to constant expansion and contraction of the cylinder head in cold weather climates causing rapid oil loss. Continued operation of the engine could result in engine damage, and in the worst case, an engine compartment fire from oil spilling on the exhaust system. WHAT WE WILL DO? To correct this condition, your dealer will install a camshaft plug retaining plate. This service will be performed for you at no charge. WHAT YOU SHOULD DO? Please contact your local Isuzu dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle. Presentation of this letter to your dealer will assist in making the necessary correction in the shortest possible time. Please have your dealer refer to Campaign Bulletin SB94-O1-0o2. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. Your Isuzu dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed serviced date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the appropriate Isuzu Regional office listed in the back of the Owner's Manual or the National Customer Relations Office, American Isuzu Motors Inc., P.O. Box 2480, City of Industry, CA 91746-0480, or call 1-800-255-6727. After contacting your dealer or Regional Office or National Office, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street S.W., Washington, D.C. 20590; or call 1-800-424-9393 (Washington D.C. residents can call 366-0123). We are sorry to cause you this inconvenience; however, in the interest of your safety, it is very important that your vehicle be returned to your Isuzu dealer as soon as possible for repair. IMPORTANT: If you have sold or traded your Isuzu vehicle, please enter the owners name and address, if known, on the enclosed "Change of information" postcard and drop it in the mail. Postage has already been paid. We will contact the new owner. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1208 Camshaft Oil Seal: Service and Repair Oil Seal Installation Apply engine oil to the camshaft oil seal lip and install new camshaft oil seal with Camshaft oil seal installer J-39203. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Transmission assembly. Refer to transmission and drivetrain. 2. Flywheel. 3. Rear oil seal. - Remove using a seal puller. NOTE: Take care not to damage the crankshaft or oil seal retainer when removing oil seal. INSTALLATION 1. Rear oil seal [3] - Apply engine oil to the oil seal lip, and install oil seal using installer: J-39201. 2. Flywheel [2] - Clean tapped holes in the crankshaft. - Remove oil on crankshaft and flywheel mounting surface. NOTE: ^ Do not reuse the bolts. ^ Do not apply oil or thread lock to the bolts. - Tighten bolts to 54 Nm (40 ft. lbs.). 3. Transmission [1] Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1212 CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. Besides, take care that dowel positions are different between the manual transmission and the automatic transmission. If assembled in the condition that dowels have not been mounted in the specified positions, it results in the transmission broken. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Oil Seal <--> [Front Crankshaft Seal] > Component Information > Service and Repair Timing Cover Oil Seal: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove timing belt. See: Timing Components/Timing Belt Then remove crankshaft pulley hub. 4. Using care not to damage crankshaft or seal housing, pry out seal using a suitable tool. 5. Reverse procedure to install, noting the following: a. Lubricate sealing lips of new seal before installing. b. Use seal driver tool No. J-35269, or equivalent to install new seal. c. Tighten bolts to specification. 6. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update Timing Belt: Technical Service Bulletins Timing Belt Installation - Manual Update BULLETIN NUMBER SB92-01-010 ISSUE DATE November 12, 1992 GROUP ENGINE TROOPER (UX) TIMING BELT INSTALLATION (WORKSHOP MANUAL CORRECTION) (This Service Bulletin supersedes SB92-01-006) AFFECTED VEHICLES 1992-93 Trooper (UX) models. SERVICE INFORMATION The timing belt installation procedure is not accurately described in the Workshop Manuals. This Service Bulletin contains the corrected timing belt installation procedure for the referenced Workshop Manual pages. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update > Page 1221 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update > Page 1222 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Timing Belt Installation - Manual Update > Page 1223 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1224 Timing Belt: Testing and Inspection TIMING BELT INSPECTION Visual check 1. The belt must be replaced if cracks or lacerations are found in the side and rear faces. 2. replacement is necessary when abnormal wear is found in the side face. 3. Replacement is necessary when belt fabric is found to be cracked or disintegrated. 4. Replacement is also necessary when cogs are found to have abnormal wear. 5. Take measurements at 3 - 5 points around the circumference of the belt The belt must be replaced even if a single measurement is beyond the limit. Limit of rubber hardness - 90 (HS) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1225 Timing Belt: Service and Repair The DOHC and SOHC engines both use the same Service and Repair procedure from Isuzu. Make note that the DOHC and SOHC engines both use a single gear for the camshaft but use different alignment marks. Removal Preparation: Battery ground cable. 1. Air cleaner assembly 2. Radiator upper fan shroud - Remove from radiator. 3. Cooling fan assembly - Remove four nuts, then the cooling fan assembly. 4. Power steering pump drive belt 5. Air conditioning compressor drive belt 6. Generator drive belt. 7. Fan pulley assembly. 8. Crankshaft pulley assembly - Using special tool J-8614-O1, hold crankshaft pulley. - Remove center bolt, then the pulley. 9. Oil cooler hose - Remove two cooler hose bracket fixing bolts on the timing cover. 10. Timing belt cover. 11. Pusher. CAUTION: The Pusher prevents air from entering the oil chamber. Its rod must always be facing upward. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1226 12. Timing belt - To prevent the timing belt from getting out of position, put the alignment mark on the cam pulley, the crankshaft pulley and the timing belt before removing the timing belt. CAUTIONS: 1. Do not bend or twist the belt, otherwise its core could be damaged. The belt should not be bent at a radius less than 3Omm. 2. Do not allow oil or other chemical substances to come in contact with the belt. They will shorten the belt life. 3. Do not attempt to pry or stretch the belt with a screwdriver or any other tool during installation. 4. Store timing belt in a cool and dark place. Never expose the belt to direct sunlight or heat. INSTALLATION 12. Timing Belt 1. Align groove of crankshaft timing pulley with mark on oil pump. 2. Align the marks on the camshaft timing pulleys with the corresponding dots on the front plate. NOTE:When timing marks are aligned, no pistons will be on T.D.C. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1227 3. Install timing belt. Align the dotted alignment mark on the timing belt with the mark on the crankshaft gear. NOTE:For correct belt installation, the letters the belt must be able to be read as viewed from the front of the vehicle. It is recommended for easy installation that the belt be secured with double clips after it is installed to each pulley. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1228 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1229 4. Align the alignment mark (white line) on the timing belt with the alignment mark on the RH bank camshaft timing pulley (on the left side as viewed from the front of the vehicle). Secure the belt with a double clip. 5. Turn the crankshaft counterclockwise to remove the belt slack between the crankshaft timing pulley and the RH bank camshaft timing pulley. 6. Install the belt on the water pump pulley. 7. Install the belt on the idle pulley. 8. Align the alignment mark (white line) on the timing belt with the alignment mark on the LH bank camshaft timing pulley. (If the belt is difficult to install, turn the camshaft pulley slightly counterclockwise.) 9. Turn the crankshaft pulley clockwise to give some slack between the crankshaft timing pulley and the RH bank camshaft timing pulley. 10. Install the pusher while pushing the tension pulley to the belt. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1230 11. Pull out the pin from the pusher. Fig. 16 Belt tension pusher installation NOTE:When reusing the pusher, press the pusher to retract the rod (1.4 mm piano wire). 12. Remove double clips from pulleys. Temporarily install the crankshaft pulley. Turn the crankshaft pulley clockwise by two turn and make sure that the rod protrusion is within the standard. Standard: ............................................................................................................................................. ................................ 4 - 6 mm (0.16 - 0.24 in) 13. If out of standard, remove pusher, loosen adjusting bolt, and readjust. Repeat from step 11. Tighten adjusting bolt to the specified torque. Torque: ................................................................................................................................................ ....................................... 42 Nm (31 ft lbs) 11. Pusher - Tighten bolts to the specified torque. Torque: ................................................................................................................................................ ....................................... 19 Nm (14 ft lbs) 9. Timing belt cover - Remove crankshaft pulley that was installed in step 12. - Tighten bolts to the specified torque. Torque: ................................................................................................................................................ ....................................... 17 Nm (12 ft lbs) 9. Oil cooler hose - Tighten oil cooler hose bracket bolts to the specified torque. Torque: ................................................................................................................................................ ....................................... 22 Nm (16 ft lbs) 8. Crankshaft pulley - Using special tool J-8614-01, hold the crankshaft pulley. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Technical Service Bulletins > Page 1231 - Tighten center bolt to the specified torque. Torque: ................................................................................................................................................ ................................... 167 Nm (123 ft lbs) 7. Fan pulley assembly - Tighten fixing bolt to the specified torque. Torque: ................................................................................................................................................ ....................................... 22 Nm (16 ft lbs) 6. Generator drive belt. - Engage and adjust 5. Air Conditioning drive belt - Engage and adjust 4. Power steering pump drive belt - Engage and adjust 3. Cooling fan assembly - Tighten nuts to the specified torque. Torque: ................................................................................................................................................ ........................................ 8 Nm (69 in lbs) 2. Radiator upper fan shroud 1. Air cleaner assembly Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications > Torque Specifications Timing Belt Tensioner: Specifications Tensioner Adjusting Bolt 31 ft.lb Tension Pusher Bolts 14 ft.lb Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications > Torque Specifications > Page 1236 Timing Belt Tensioner: Specifications Tension Pusher Rod Protrusion Standard 0.16 - 0.24 in Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Belt Cover Bolts 12 ft.lb Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Component Location - SOHC At back of engine. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications ECM controlled, not adjustable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 1248 Air/Fuel Mixture: Adjustments The air/fuel mixture is ECM controlled and there is no provision for adjustment. Refer to COMPUTERS AND CONTROL SYSTEMS. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications ECM controlled, not adjustable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1252 Idle Speed: Adjustments The idle speed is Engine Control Module (ECM) controlled and there is no provision for adjustment. Refer to Computers and Control Systems/Testing and Inspection if there is a problem with the idle speed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Testing and Inspection Air Filter Element: Testing and Inspection ^ Remove air filter element from air cleaner box and visually inspect. ^ Replace filter if it appears dirty or oil saturated, or if scheduled maintenance interval has been reached. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Replace all pipes with the same pipe and fittings that were removed. Do not reuse "O" rings. Always replace. - Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair. - Adhere to all Notices and Cautions. NOTE: If available, use system bleed valve (schrader) to relieve pressure. NYLON FUEL PIPE CAUTIONS: In order to reduce the risk of fire and personal injury observe the following items: - Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes - Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115° C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1261 Fuel Pressure Release: Service and Repair 1. Remove fuel filler cap. 2. Remove fuel pump relay from underhood relay center. 3. Start engine and allow to stall. 4. Crank engine for an additional 30 seconds. 5. Remove negative battery cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1 2 3 4 5 6 Firing Order: 1 - 2 - 3 - 4 - 5 - 6 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order: 1 2 3 4 5 6 Firing Order: 1 - 2 - 3 - 4 - 5 - 6 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 > Spark Plug Tube - Oil Seepage Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Seepage BULLETIN NUMBER: SB97-01-L003 ISSUE DATE: JUNE 1997 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 3.2L V6 SOHC ENGINE SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 3.2L V6 SOHC engine. SERVICE PROCEDURE When servicing affected vehicles experiencing oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface, be sure to refer only to Service Bulletin SB96-01-L005, issued 9/96. The authorized repair for affected vehicles experiencing this condition, is to replace the original spark plug wire set with a new type wire set which features an improved bushing designed to control oil seepage at the spark plug tube-to-cylinder head interface. SB96-01-L005 describes this authorized repair. Do not refer to Service Bulletin SB96-01-L004, issued 4/96, to repair this condition. It is not the authorized repair. SB96-01-L004 is strictly intended to provide detailed service and warranty information when spark plug tube replacement is required. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Ignition Cable: Customer Interest Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 > Spark Plug Tube - Oil Seepage Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Seepage BULLETIN NUMBER: SB97-01-L003 ISSUE DATE: JUNE 1997 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 3.2L V6 SOHC ENGINE SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 3.2L V6 SOHC engine. SERVICE PROCEDURE When servicing affected vehicles experiencing oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface, be sure to refer only to Service Bulletin SB96-01-L005, issued 9/96. The authorized repair for affected vehicles experiencing this condition, is to replace the original spark plug wire set with a new type wire set which features an improved bushing designed to control oil seepage at the spark plug tube-to-cylinder head interface. SB96-01-L005 describes this authorized repair. Do not refer to Service Bulletin SB96-01-L004, issued 4/96, to repair this condition. It is not the authorized repair. SB96-01-L004 is strictly intended to provide detailed service and warranty information when spark plug tube replacement is required. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1291 Ignition Cable: Specifications Resistance between terminal ends. Cable # ................................................................................................................................................ .............................................................. x 1000 ohms 1 ........................................................................................................................................................... ................................................................... 6.4 - 14.9 2 ........................................................................................................................................................... ................................................................... 5.7 - 13.1 3 ........................................................................................................................................................... ................................................................... 6.2 - 14.4 4 ........................................................................................................................................................... ................................................................... 5.8 - 13.3 5 ........................................................................................................................................................... ................................................................... 6.4 - 14.9 6 ........................................................................................................................................................... ................................................................... 6.9 - 16.0 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1292 Spark Plug Wires Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1293 Ignition Cable: Description and Operation Ignition Wire PURPOSE Conduct high voltage from the ignition coil to spark plugs. LOCATION Between the coils and spark plugs. CONSTRUCTION The ignition wires have an internal resistance to suppress radio static and to eliminate static that may interfere with sensitive computer components. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1294 Ignition Cable: Testing and Inspection Using an ohm meter, check the resistance between ignition wire terminal ends. Cable # ................................................................................................................................................ .............................................................. x 1000 ohms 1 ........................................................................................................................................................... ................................................................... 6.4 - 14.9 2 ...................................................................... ........................................................................................................................................................ 5.7 - 13.1 3 ................................................................................................................................................ .............................................................................. 6.2 - 14.4 4 ........................................................... .............................................................................................................................................................. ..... 5.8 - 13.3 5 .................................................................................................................................... .......................................................................................... 6.4 - 14.9 6 ............................................... .............................................................................................................................................................. ................. 6.9 - 16.0 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1295 Ignition Cable: Service and Repair Spark Plug Wires Remove wires. Spark Plug Wire Index Be sure to refit to correct terminal. NOTE: Do not cross, twist or pull spark plug wires. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Spark Plug: All Technical Service Bulletins Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement Procedure BULLETIN NUMBER: SB96-01-L004 ISSUE DATE: APRIL 1996 GROUP: ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT (Supersedes SB96-01-L001, to include sublet allowance information) APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug contact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1308 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 64 mm +/- 0.5 mm 2.52 in +/- .02 in Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1309 FLAT RATE MANUAL UPDATE INFORMATION Use the following new labor operation: Use Sublet Code B8 ($8.40) for Loctite 290 reimbursement. Dealers are allowed to claim one 8 milliliter bottle of Loctite 290 per VIN. This sublet code does not require dealer or Zone Service & Parts Manager authorization. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement BULLETIN NUMBER SB95-01-L002 ISSUE DATE AUGUST 1995 GROUP ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug intact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 1314 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 1315 ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 65 mm +/- 0.5 mm (2.56 in. +/- .02 in). FLAT RATE MANUAL UPDATE INFORMATION Use the new labor operation as shown. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation Spark Plug: Customer Interest Spark Plug Tube - Oil Accumulation BULLETIN NUMBER: SB96-01-L005 ISSUE DATE: SEPTEMBER 1996 GROUP: ENGINE 1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL ACCUMULATION AFFECTED VEHICLES 1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine. SERVICE INFORMATION Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage at the spark plug tube-to-cylinder head interface. To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug wire set (see Parts Information section) using the procedure described in this Service Bulletin. The new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug tube-to-cylinder interface. SERVICE PROCEDURE Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts Information section) in accordance with service procedures in appropriate Workshop Manual. For Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual. PARTS INFORMATION Part No. Description Quantity Required 8-97163-999-0 High Tension 4 Cable Kit (UX) (spark plug wire set) 8-97164-006-0 High Tension 1 Cable Kit (UC) (spark plug wire set) FLAT RATE MANUAL UPDATE INFORMATION Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire set. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement Procedure BULLETIN NUMBER: SB96-01-L004 ISSUE DATE: APRIL 1996 GROUP: ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT (Supersedes SB96-01-L001, to include sublet allowance information) APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug contact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1326 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 64 mm +/- 0.5 mm 2.52 in +/- .02 in Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1327 FLAT RATE MANUAL UPDATE INFORMATION Use the following new labor operation: Use Sublet Code B8 ($8.40) for Loctite 290 reimbursement. Dealers are allowed to claim one 8 milliliter bottle of Loctite 290 per VIN. This sublet code does not require dealer or Zone Service & Parts Manager authorization. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement BULLETIN NUMBER SB95-01-L002 ISSUE DATE AUGUST 1995 GROUP ENGINE TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT APPLICABLE VEHICLES Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine. SERVICE INFORMATION If a spark plug tube (cylinder head tube) must be replaced, use the following procedure: DISASSEMBLY 1. Spark Plug Tube ^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A and 1B). Leave spark plug intact. CLEAN ^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use motorized wire brush for cleaning. REASSEMBLY 1. Spark Plug Tube ^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 1332 ^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 1333 ^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 65 mm +/- 0.5 mm (2.56 in. +/- .02 in). FLAT RATE MANUAL UPDATE INFORMATION Use the new labor operation as shown. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1334 Spark Plug: Specifications Spark plug gap .................................................................................................................................... .............................. 0.040 - 0.043 in (1.05 - 1.1 mm) Spark plug torque ................................................................................................................................ ...................................................... 14 ft lb (19 Nm) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1335 Spark Plug: Description and Operation Spark Plug Cutaway View PURPOSE Spark plugs allow high-voltage secondary current to arc across a small air gap to ignite the air/fuel mixture in the combustion chamber. Spark Plug Temperature HEAT RANGE The temperature of the spark plug is determined by the length of the insulator and the size of the heatsink area. The longer the insulator, the smaller the heatsink area will be. This causes the spark plug to be hotter. The heat range of the plug is determined by its ability to dissipate heat created during combustion. If too cold a plug is used, the possibility of fouling is increased. A plug that is too hot can cause preignition. Hotter plugs tend to burn cleaner with less deposit build-up. They can be used for stop-start city driving, but not for extended high speed or load conditions as engine damage can occur. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1336 Spark Plug: Testing and Inspection INSPECTION - Check the electrodes and insulators for cracks. Replace if faulty. - Check the electrodes for wear and replace as necessary. - Check the gaskets for damage and replace as necessary. - Check insulation resistance with an ohmmeter. Replace if defective. SPARK PLUG INSULATION RESISTANCE 50 M ohms - Check spark plug gap. Adjust or replace as necessary. SPARK PLUG ELECTRODE GAP 1.05 mm (0.040 in) - If spark plug fouling is excessive, check fuel and electrical systems for possible causes. If those systems are normal, install spark plugs of a higher heat range. - If burning of the electrodes or insulator is considerable, install spark plugs of a lower heat range. SOOTY SPARK PLUGS If the electrodes and insulators are fouled with carbon or oil, the engine will operate efficiently. There are a number of possible causes: Rich fuel mixture. - Retarded ignition timeing. - Excessive engine wear (oil in cylinders). - Incorrect plug gap. BLISTERED OR SCORCHED SPARK PLUGS This condition is caused by excessive temperature at the spark plug. Common causes are: Lean fuel mixture. - Advanced ignition timing. - Incorrect plug gap. - Incorrect plug heat range. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection 1. Start and warm engine to operating temperature. 2. Remove all spark plugs and apply a few drops of engine oil into spark plug holes. 3. Relieve fuel system pressure as outlined under Precautions. 4. Disable ignition system, by removing ignition fuse. 5. Connect a tachometer and crank engine, ensure cranking speed is 300 RPM or higher. 6. Install compression gauge, then crank engine with throttle wide open. 7. Minimum pressure should be 128 psi. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1348 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1349 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1350 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1351 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1357 Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1358 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1359 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1360 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1361 Valve Clearance: By Symptom Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1362 None: This is not a warranty matter (see POSSIBLE CAUSE). Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1363 Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1364 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1365 Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Technical Service Bulletin # SB00-01-S009 Date: 000901 Engine Valve Train - Ticking Noise BULLETIN NUMBER: SB00-01-S009 ISSUE DATE: SEPTEMBER 2000 GROUP: ENGINE TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002) NOTE: This service bulletin is being revised to update parts information. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1366 AFFECTED VEHICLES Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models SERVICE INFORMATION Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the valvetrain during normal operation. Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up inside. This condition results from exceeding the required oil and filter change intervals. Severe driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's Manual or Workshop Manual for details.) Correction: A typical repair for the condition may involve the replacement of the affected rocker arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component. NOTE: Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30 synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the varnish that is preventing hydraulic lash adjuster piston travel. PARTS INFORMATION WARRANTY CLAIM INFORMATION None: This is not a warranty matter (see POSSIBLE CAUSE). Service Procedure 1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase with 0W-30 Mobil 1 synthetic engine oil. 2. With the engine warm, run it at 2,500 rpm for 30 minutes. ^ If the ticking noise goes away, return the vehicle to the customer. ^ If the ticking noise persists, proceed with step 3. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1367 3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is noisy. Once you have determined the location, turn the key off. (Figure 1) 4. Remove the cylinder head cover on the noisy bank. 5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2) NOTE: Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate Workshop Manual for additional troubleshooting procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1368 6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts, which require timing belt removal). 7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers. (Figure 4) IMPORTANT: Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When replacing an exhaust rocker arm, replace its intermediate rocker arm too. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1369 8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil may come out of the check ball hole. (Figure 5) 9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure 6) 10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic Lash Adjuster. (Figure 7) 11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the Hydraulic Lash Adjuster with oil. 12. Reinstall the Hydraulic Lash Adjuster O-Ring. 13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1 synthetic engine oil, then push the Hydraulic Lash Adjuster back into place. 14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or compress). NOTE: Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This may cause the engine to run rough for a short period after starting. To prevent this, select one cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the valves spring and cam will collapse the Hydraulic Lash Adjuster permanently. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1370 15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only. 16. Start the engine and listen for noise. 17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also recommend to use minimum oil rating of: API Service SG, but SJ is preferred. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Page 1371 Valve Clearance: Specifications Stem Diameter: Intake ................................................................................................................................................... ...................................... 0.2346-0.2323 inches Exhaust ..................................................................... ................................................................................................................. 0.2343-0.2323 inches Face Angle, Degrees ........................................................................................................................... ............................................................................... 45 Valve Clearance: Intake ................................................................................................................................................... .................................................................. [01] Exhaust ...................................................................... ............................................................................................................................................ [01] [01] -- Hydraulic lifters, no adjustment is necessary. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Technical Service Bulletins > Page 1372 Valve Clearance: Adjustments These engines use hydraulic valve lifters. No valve adjustment is possible. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Water Pump - Installation (Manual Revision) Water Pump: Technical Service Bulletins Water Pump - Installation (Manual Revision) BULLETIN NUMBER: SB97-01-L009 ISSUE DATE: NOVEMBER 1997 GROUP: ENGINE 1992-97 TROOPER (UX) AND 1993-97 RODEO (UC) 3.2L V6 ENGINE WATER PUMP ASSEMBLY INSTALLATION (Workshop Manual Revision) AFFECTED VEHICLES 1992-97 Trooper (UX) models. 1993-97 Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION The water pump installation procedure contained in Section 6B - Engine Cooling (1992-97 Trooper) and in Section 6B1A - Engine Cooling (1993-97 Rodeo) of the listed Workshop Manuals, has been revised. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1377 The water pump installation procedure has been revised to include a note to apply LOCTITE 262, or equivalent, to the No. 3 water pump retaining bolt threads to prevent oil leakage. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1378 This Service Bulletin contains the revised pages to the referenced Workshop Manuals. Revisions to the affected pages are shown. Attach the enclosed pages to the referenced Workshop Manual pages. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Page 1379 Water Pump: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then insulate cable end with electrical tape. 3. Drain engine coolant from radiator. 4. Remove timing belt. 5. Remove idler pulley, then the water pump. Fig. 69 Water Pump Tightening Sequence 6. Reverse procedure to install, noting the following: a. Ensure all gasket material has been removed from engine block sealing surface. b. Torque water pump retaining bolts in sequence shown, Fig. 69, to 13 ft. lbs. c. Tighten idler pulley retaining bolt to specification. Torque: N.m (lb.ft) 42 (31) 7. Timing Belt - Install timing belt and adjust the belt tension. See: Timing Components/Timing Belt/Service and Repair - connect radiator inlet hose and replenish coolant. - Connect battery ground cable. 8. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Acceptable for Use Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Acceptable for Use BULLETIN NUMBER SB96-14-L002 ISSUE DATE JANUARY 1996 GROUP MISCELLANEOUS PROPYLENE GLYCOL - BASED ENGINE COOLANT (Supersedes SB94-14-005) AFFECTED VEHICLES All Isuzu passenger, sport utility, and light truck models. SERVICE INFORMATION Isuzu has determined that propylene glycol-based engine coolants, such as Safe Brands' Sierra engine coolant, will perform adequately under most vehicle operating conditions. As a result, propylene glycol-based engine coolants may be used in Isuzu vehicles. A few important points to remember regarding propylene glycol-based engine coolants: ^ Freeze/boil point levels for propylene glycol are different than for ethylene glycol. ^ To accurately determine the freeze/boil protection level, it is imperative that the coolants not be mixed. ^ Prior to adding propylene glycol engine coolant to the cooling system, all ethylene glycol coolant must be removed. ^ When changing the coolant to propylene glycol, be certain to thoroughly flush the heater core and block as well as the radiator. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Acceptable for Use > Page 1385 Coolant: Technical Service Bulletins Coolant - Propylene Glycol Not Approved by Isuzu BULLETIN NUMBER SB94-14-005 ISSUE DATE DECEMBER 1994 GROUP MISCELLANEOUS PROPYLENE GLYCOL-BASED ENGINE COOLANT WARNING AFFECTED VEHICLES All Isuzu passenger and light duty models. SERVICE INFORMATION Some new propylene glycol-based engine coolants, such as Safe Brands' Sierra engine coolant, have recently been marketed in the automotive service industry as "environmentally safe" alternatives to conventional ethylene glycol-based engine coolants. Propylene glycol-based engine coolants are not approved by Isuzu for use in Isuzu vehicles. Propylene glycol-based engine coolants do not meet Isuzu engine coolant specifications. Use of propylene glycol-based engine coolants in Isuzu vehicles can cause the following: ^ Reduced heater and defroster performance. ^ Decreased boil protection and freeze protection. ^ Decreased cylinder head heat transfer. ^ Corrosion damage to cooling system metals (if mixed with ethylene glycol-based engine coolant). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity, Quarts: Manual Transmission .......................................................................................................................... .................................................................... 9.3 Automatic Transmission ........................................... ............................................................................................................................................... 9.0 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1388 Coolant: Fluid Type Specifications Type .................. Mixture of water and good quality ethylene glycol base type antifreeze. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair Radiator Cooling Fan Motor: Service and Repair 1. Remove upper radiator hose, then loosen water pump drive belt. Fig. 1 Lower Fan Shroud Retaining Clips 2. Remove radiator fan shroud by releasing two clips holding lower shroud to upper shroud, Fig. 1, then remove four bolts holding upper shroud to radiator and lift shroud out. Fig. 2 Fan Clutch To Water Pump Nuts 3. Remove nuts holding fan clutch to water pump hub, then lift out fan and clutch assembly. . Reverse procedure to install torque fan clutch to water pump flange nuts to 7.4 ft. lbs., Fig. 2. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Temperature ........................................................................................................................................ ............................................................... Resistance -18°C (0°F) .......................................................................................................................................... .................................................................. 25K ohms -7°C (20°F) ...................................................... ................................................................................................................................................... 13.5K ohms 4°C (40°F) .................................................................................................................................. .......................................................................... 7.5K ohms 20°C (68°F) ............................................ .............................................................................................................................................................. 3.4K ohms 38°C (100°F) ..................................................................................................................... ................................................................................... 1.8K ohms 70°C (160°F) ................................. .............................................................................................................................................................. ........... 450 ohms 100°C (212°F) ......................................................................................................... ............................................................................................... 185 ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1397 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1398 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature Sensor ECT Sensor PURPOSE Provides engine temperature information to the Engine Control Module (ECM). LOCATION Rear of engine. OPERATION The ECM supplies a 5V signal to the sensor and measures voltage variation. By measuring this variation, the ECM measures coolant temperature. This input is a factor in calculations involving most ECM controlled systems. CONSTRUCTION The coolant temperature sensor is a thermistor (a device whose resistance changes with temperature) mounted in the engine cooling system. Low temperature produces high resistance (100K ohms at -40°C / -40°F) while high temperature produces low resistance (70 ohms at 130°C / 266°F). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1399 Engine Temperature Sensor: Service and Repair ECT Sensor REMOVAL NOTE: Care must be taken when handling Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. - Negative battery cable. - Drain engine coolant system. - Intake manifold assembly. Refer to Fuel Delivery and Air Induction. - Electrical connector - ECT sensor. Remove from rear of engine coolant transfer tube. INSTALLATION - ECT sensor. Apply sealer or equivalent to threads only. - Tighten the ECT sensor to the specified torque Torque 30 N-m (22 lb-ft) - ECT sensor connector - Intake manifold assembly - Negative battery cable. - Refill engine coolant system. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair HEATER UNIT/CORE Removal Procedure 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable and drain cooling system. 3. Remove rear seat, then disconnect heater hoses from rear heater assembly. 4. Remove heater assembly attaching bolts, disconnect blower motor electrical connector, then remove rear heater assembly from vehicle. 5. Remove clamps and remaining heater hoses. 6. Disconnect blower resistor wiring harness, then remove attaching screw and resistor. 7. Remove seal, then the left and right support brackets. 8. Remove attaching screws and front duct assembly. 9. Remove case retaining clips, separate case, then remove heater core. 10. Reverse procedure to install. 11. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair The OEM service manual does not provide service and repair information for this component. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Needle Does Not Move Temperature Gauge: Testing and Inspection Needle Does Not Move Fig. 8 Temperature Gauge Diagnosis: Needle Does Not Move Refer to Fig. 8, for temperature gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1411 Temperature Gauge: Testing and Inspection Gauge Reading Is Too Low Fig. 9 Temperature Gauge Diagnosis: Gauge Reading Is Too Low Refer to Fig. 9, for temperature gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1412 Temperature Gauge: Testing and Inspection Needle Goes Past 'H' Fig. 10 Temperature Gauge Diagnosis: Needle Goes Past "H" Refer to Fig. 10, for temperature gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Drain engine coolant from radiator. Fig. 73 Radiator Replacement 4. Remove automatic transmission oil cooler lines, Fig. 73. 5. Remove radiator hoses. 6. Remove lower cooling fan guide. 7. Remove reserve tank hose from filler neck. 8. Remove support bracket. 9. Remove radiator. 10. Reverse procedure to install. 11. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Radiator Cap Relief Pressure, Lbs. ..................................................................................................... ............................................................................... 15 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Temperature ........................................................................................................................................ ............................................................... Resistance -18°C (0°F) .......................................................................................................................................... .................................................................. 25K ohms -7°C (20°F) ...................................................... ................................................................................................................................................... 13.5K ohms 4°C (40°F) .................................................................................................................................. .......................................................................... 7.5K ohms 20°C (68°F) ............................................ .............................................................................................................................................................. 3.4K ohms 38°C (100°F) ..................................................................................................................... ................................................................................... 1.8K ohms 70°C (160°F) ................................. .............................................................................................................................................................. ........... 450 ohms 100°C (212°F) ......................................................................................................... ............................................................................................... 185 ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1424 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1425 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature Sensor ECT Sensor PURPOSE Provides engine temperature information to the Engine Control Module (ECM). LOCATION Rear of engine. OPERATION The ECM supplies a 5V signal to the sensor and measures voltage variation. By measuring this variation, the ECM measures coolant temperature. This input is a factor in calculations involving most ECM controlled systems. CONSTRUCTION The coolant temperature sensor is a thermistor (a device whose resistance changes with temperature) mounted in the engine cooling system. Low temperature produces high resistance (100K ohms at -40°C / -40°F) while high temperature produces low resistance (70 ohms at 130°C / 266°F). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1426 Engine Temperature Sensor: Service and Repair ECT Sensor REMOVAL NOTE: Care must be taken when handling Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. - Negative battery cable. - Drain engine coolant system. - Intake manifold assembly. Refer to Fuel Delivery and Air Induction. - Electrical connector - ECT sensor. Remove from rear of engine coolant transfer tube. INSTALLATION - ECT sensor. Apply sealer or equivalent to threads only. - Tighten the ECT sensor to the specified torque Torque 30 N-m (22 lb-ft) - ECT sensor connector - Intake manifold assembly - Negative battery cable. - Refill engine coolant system. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Needle Does Not Move Temperature Gauge: Testing and Inspection Needle Does Not Move Fig. 8 Temperature Gauge Diagnosis: Needle Does Not Move Refer to Fig. 8, for temperature gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1431 Temperature Gauge: Testing and Inspection Gauge Reading Is Too Low Fig. 9 Temperature Gauge Diagnosis: Gauge Reading Is Too Low Refer to Fig. 9, for temperature gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Needle Does Not Move > Page 1432 Temperature Gauge: Testing and Inspection Needle Goes Past 'H' Fig. 10 Temperature Gauge Diagnosis: Needle Goes Past "H" Refer to Fig. 10, for temperature gauge diagnosis. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature ...................................................................................................... .......................................................................... 170°F Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1436 Thermostat: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable. 3. Drain coolant from radiator. 4. Disconnect thermoswitch electrical connector, then the upper radiator hose from thermostat housing. 5. Remove thermostat housing and thermostat from engine assembly. Note installation position of jiggle valve before removing thermostat. 6. Reverse procedure to install, noting the following: a. Ensure thermostat housing sealing surfaces are free of old gasket material. b. Install thermostat with jiggle valve positioned at 12 o'clock. c. Tighten thermostat housing retaining bolts to specification. 7. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Water Pump - Installation (Manual Revision) Water Pump: Technical Service Bulletins Water Pump - Installation (Manual Revision) BULLETIN NUMBER: SB97-01-L009 ISSUE DATE: NOVEMBER 1997 GROUP: ENGINE 1992-97 TROOPER (UX) AND 1993-97 RODEO (UC) 3.2L V6 ENGINE WATER PUMP ASSEMBLY INSTALLATION (Workshop Manual Revision) AFFECTED VEHICLES 1992-97 Trooper (UX) models. 1993-97 Rodeo (UC) models equipped with 3.2L V6 engine. SERVICE INFORMATION The water pump installation procedure contained in Section 6B - Engine Cooling (1992-97 Trooper) and in Section 6B1A - Engine Cooling (1993-97 Rodeo) of the listed Workshop Manuals, has been revised. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1441 The water pump installation procedure has been revised to include a note to apply LOCTITE 262, or equivalent, to the No. 3 water pump retaining bolt threads to prevent oil leakage. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1442 This Service Bulletin contains the revised pages to the referenced Workshop Manuals. Revisions to the affected pages are shown. Attach the enclosed pages to the referenced Workshop Manual pages. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Page 1443 Water Pump: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then insulate cable end with electrical tape. 3. Drain engine coolant from radiator. 4. Remove timing belt. 5. Remove idler pulley, then the water pump. Fig. 69 Water Pump Tightening Sequence 6. Reverse procedure to install, noting the following: a. Ensure all gasket material has been removed from engine block sealing surface. b. Torque water pump retaining bolts in sequence shown, Fig. 69, to 13 ft. lbs. c. Tighten idler pulley retaining bolt to specification. Torque: N.m (lb.ft) 42 (31) 7. Timing Belt - Install timing belt and adjust the belt tension. See: Engine/Timing Components/Timing Belt/Service and Repair - connect radiator inlet hose and replenish coolant. - Connect battery ground cable. 8. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation Three-Way Catalytic Converter PURPOSE To reduce exhaust emissions of NOx, HC, and CO. LOCATION In the exhaust tubing. OPERATION A three-way catalytic converter is used downstream of the exhaust manifold to reduce oxides of nitrogen (NOx) and oxidize hydrocarbons (HC) and carbon monoxide (CO). Emissions are converted into carbon dioxide, water vapor and nitrogen. CONSTRUCTION The converter contains the catalyst elements platinum, rhodium and palladium which promote oxidation and reduction reactions at high temperatures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1448 Catalytic Converter: Testing and Inspection CATALYTIC CONVERTER INSPECTION 1. Visually inspect exterior of converter. If severe damage is noted, such a dented, crushed or rusted out shell, replace converter. 2. Whenever converter is removed from vehicle, check ceramic element through exhaust inlet and outlet. If element is clogged, melted or otherwise damaged, replace converter. Exhaust System Back Pressure Check (Using Oxygen Sensor Mounting Hole) RESTRICTED EXHAUST SYSTEM CHECK AT OXYGEN SENSOR 1. Remove oxygen sensor. 2. In place of the sensor, install a Boroughs exhaust backpressure tester (BT8515 or BT8603) or equivalent 3. With engine idling at normal operating temperature, the gauge reading should not exceed 8.6 kPa (1.25 psi). 4. Increase engine speed to 2000 rpm. Gauge reading should not exceed 20.7 kPa (3 psi). 5. If backpressure at either speed exceeds specification, a restricted exhaust system is indicated. 6. Inspect exhaust system for a collapsed pipe, heat distress or possible internal muffler failure. 7. If no obvious reasons for excessive exhaust system backpressure are found, suspect a restricted catalytic converter. 8. After completing test, coat threads of oxygen sensor with anti-seize compound prior to reinstallation. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1449 Catalytic Converter: Service and Repair Catalytic Converter Replacement 1. Raise and support vehicle in a safe manner. 2. Check that converter is cool enough to work with. 3. Remove bolts at front and rear of converter, remove converter and gaskets. 4. When reinstalling original or new converter, use new gaskets at front and rear pipe connections. 5. When installing new gaskets, ensure that the "U" marks on the gaskets are oriented at the top. 6. Install bolts and tighten to complete installation. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair Exhaust Manifold: Service and Repair 1. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. 2. Disconnect battery ground cable, then insulate cable end with suitable electrical tape. 3. If removing left manifold, remove EGR pipe. 4. Disconnect front exhaust pipe from manifold. 5. Remove five heat protector retaining bolts, then the heat protector. 6. Remove seven exhaust manifold retaining nuts, then the manifold. 7. Reverse procedure to install. 8. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Spark Control Module > Component Information > Description and Operation Electronic Spark Control Module: Description and Operation KS Circuit PURPOSE Provides a signal to the ECM when engine detonation occurs. LOCATION Knock sensor is mounted in engine block under intake manifold. The solid state module is near the upper R.H. corner of the inner fender. OPERATION When abnormal engine vibrations (spark knock) are present, sensor produces voltage signal which is received by knock sensor (KS) module. As long as KS module sees no voltage from knock sensor, KS sends a signal voltage (8 to 10 volts) to ECM which in turn provides normal spark advance. When the sensor detects a knock is generates voltage. When the KS module receives this voltage it reduce the signal to the ECM to O volts. The ECM then retards the ignition timing. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 1462 Engine Control Module: Description and Operation Inputs And Outputs PURPOSE Control unit of fuel injection system. LOCATION Under instrument panel in front of the center console OPERATION It constantly looks at information from various sensors, and controls systems that affect vehicle performance. ECM also performs diagnostic function of system. It can recognize operational problems, alert driver through "Check Engine" light, and store a code or codes which identify problem areas to aid technician in making repairs. ECM supplies either 5 or 12 volts to power various sensors or switches and controls output circuits such as fuel injectors, IAC valve, A/C clutch relay, etc. by controlling ground circuit through transistors or a "quad-driver". Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 1463 Engine Control Module: Service and Repair ECM REMOVAL - Negative battery cable - Lower trim panel at console (4 fasteners) - Air Conditioning Heater transfer tube - ABS controller electrical connector (1) (if equipt) - ABS controller (4 fasteners) (if equipt) - Four (4) fasteners for ECM bracket - ECM electrical connectors (2) - ECM from 'inder dash, bracket still attached NOTE: To prevent possible Electronic Discharge damage to the ECM, Do not touch the connector pins or soldered components on the circuit board. INSTALLATION - ECM and bracket under dash - Four (4) fasteners and tighten - Two (2) ECM electrical connectors - ABS controller and four (4) fasteners (if equipt) - ABS controller electrical connector (if equipt) - Air Conditioning Heater transfer tube - Lower trim panel at console (4 fasteners) - Negative battery cable Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1471 Relay Location Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1472 Fuel Pump Relay: Description and Operation Fuel Pump Circuit PURPOSE Allows the ECM control over fuel pump operation. Fuel Pump Relay Connector LOCATION In the fuse/relay center, in the engine compartment. OPERATION When ignition is switched "RUN" position (engine not running), ECM energizes fuel pump relay for two seconds, causing fuel pump to pressurize fuel system. If ECM does not receive ignition reference pulses (engine cranking or running) within two seconds, it will de-energize relay, stopping fuel pump. After the engine starts, the ECM uses the signal from the electronic ignition module to determine if the engine is running. If the signal is interrupted, the ECM will not energize the fuel pump. This prevents the fuel from operating when the engine is not running. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1473 Fuel Pump Relay: Testing and Inspection Fuel Pump Circuit Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1474 Chart A-5 Fuel Pump Relay Circuit Circuit Description When the ignition switch is turned "ON", the Engine Control Module (ECM) will activate the fuel pump relay and operate the in tank fuel pump. The fuel pump will operate as long as the engine is cranking or running and the ECM is receiving ignition reference pulses. If there are no reference pulses, the ECM will shut "OFF" the fuel pump within 2 seconds after key "ON". Test Description Numbers below refer to circled numbers on the diagnostic chart. 1. Checks for the presence Battery Position Voltage at switching portion of fuel pump relay. 2. Checks circuit between fuel pump relay and ground (including the fuel pump). 3. This test will confirm if voltage is available to the relay coil. Diagnostic Aids A visual inspection of wiring and connectors should be made if an intermittent problem exists. For further information, refer to Intermittent Check Procedure. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Fuse/Relay Panel Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Electronic Spark Control Module > Component Information > Description and Operation Electronic Spark Control Module: Description and Operation KS Circuit PURPOSE Provides a signal to the ECM when engine detonation occurs. LOCATION Knock sensor is mounted in engine block under intake manifold. The solid state module is near the upper R.H. corner of the inner fender. OPERATION When abnormal engine vibrations (spark knock) are present, sensor produces voltage signal which is received by knock sensor (KS) module. As long as KS module sees no voltage from knock sensor, KS sends a signal voltage (8 to 10 volts) to ECM which in turn provides normal spark advance. When the sensor detects a knock is generates voltage. When the KS module receives this voltage it reduce the signal to the ECM to O volts. The ECM then retards the ignition timing. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Coil Pack Under ignition coil pack, at front of engine. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Crankshaft Position Sensor R.H. side of engine block. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1490 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor PURPOSE Provides information such as firing order and starting timing of each ignition coil. LOCATION R.H. side of engine block. CONSTRUCTION and OPERATION The system uses a magnetic Crankshaft Position (CKP) sensor which protrudes into the block, within approximately .050" of the crankshaft reluctor. The reluctor is a special wheel cast on the crankshaft that has seven machined slots, six of which are equally spaced 60 ° apart. The seventh slot is spaced 10 ° from one of the other slots. As the reluctor rotates with the crankshaft, the slots change the magnetic field of the sensor, causing an induced voltage pulse. By counting the time between pulses, the Ignition Control Module (ICM) can recognize the pulse of the seventh slot (sync pulse). Based on this sync pulse, the module sends the reference signal to the Engine Control Module (ECM) to calculate CKP (used to fire coils in correct sequence) and engine speed. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1491 Crankshaft Position Sensor: Service and Repair REMOVE 1. Disconnect battery ground cable. Protection Shield 2. Remove exhaust and transfer protector. 3. Disconnect front propeller shaft joint. Crank Angle Sensor / Crankshaft Position Sensor 4. Disconnect wiring connector at crank angle sensor. 5. Remove mounting nut and remove sensor. REFIT 1. Lubricate O-ring on new sensor and fit to engine block. 2. Fit sensor mounting bolt and tighten to: 87 in lb (10 Nm) 3. Reconnect front propeller shaft joint and tighten to: 46 ft lb (63 Nm) 4. Refit protection shield and tighten bolts to: 27 ft lb (37 Nm) 5. Reconnect battery cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Temperature ........................................................................................................................................ ............................................................... Resistance -18°C (0°F) .......................................................................................................................................... .................................................................. 25K ohms -7°C (20°F) ...................................................... ................................................................................................................................................... 13.5K ohms 4°C (40°F) .................................................................................................................................. .......................................................................... 7.5K ohms 20°C (68°F) ............................................ .............................................................................................................................................................. 3.4K ohms 38°C (100°F) ..................................................................................................................... ................................................................................... 1.8K ohms 70°C (160°F) ................................. .............................................................................................................................................................. ........... 450 ohms 100°C (212°F) ......................................................................................................... ............................................................................................... 185 ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1495 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1496 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature Sensor ECT Sensor PURPOSE Provides engine temperature information to the Engine Control Module (ECM). LOCATION Rear of engine. OPERATION The ECM supplies a 5V signal to the sensor and measures voltage variation. By measuring this variation, the ECM measures coolant temperature. This input is a factor in calculations involving most ECM controlled systems. CONSTRUCTION The coolant temperature sensor is a thermistor (a device whose resistance changes with temperature) mounted in the engine cooling system. Low temperature produces high resistance (100K ohms at -40°C / -40°F) while high temperature produces low resistance (70 ohms at 130°C / 266°F). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1497 Engine Temperature Sensor: Service and Repair ECT Sensor REMOVAL NOTE: Care must be taken when handling Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. - Negative battery cable. - Drain engine coolant system. - Intake manifold assembly. Refer to Fuel Delivery and Air Induction. - Electrical connector - ECT sensor. Remove from rear of engine coolant transfer tube. INSTALLATION - ECT sensor. Apply sealer or equivalent to threads only. - Tighten the ECT sensor to the specified torque Torque 30 N-m (22 lb-ft) - ECT sensor connector - Intake manifold assembly - Negative battery cable. - Refill engine coolant system. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Temperature ........................................................................................................................................ ............................................................... Resistance 20°F (-7°C) .......................................................................................................................................... ............................................................... 13.5K ohms 68°F (20°C) ..................................................... ..................................................................................................................................................... 3.4K ohms 100°F (38°C) .............................................................................................................................. .......................................................................... 1.8K ohms Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1501 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1502 Intake Air Temperature Sensor: Description and Operation MAT Sensor PURPOSE Provides the Engine Control Module (ECM) with intake air temperature. The ECM uses this information to determine air density. LOCATION In the common chamber. OPERATION The ECM supplies a 5V reference signal to the sensor and by measuring the voltage change can determine the manifold air temperature. IAT sensor is also used to control spark timing and delays EGR when intake air is cold. A failure in Intake Air Temperature (IAT) sensor circuit should set a Code 23. CONSTRUCTION The Intake Air Temperature (IAT) Sensor is a thermistor (resistor) whose resistance value varies in relation to the temperature of air entering the engine. Low temperature results in high resistance (100K ohms at -40°C / -40°F); high temperature results in low resistance (70 ohms at 130°C / 266°F). Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1503 Intake Air Temperature Sensor: Service and Repair IAT Sensor And MAP Sensor REMOVAL - Negative battery cable. - Wiring connector - Disconnect connector from Intake Air Temperature (Iat) sensor. - IAT sensor INSTALLATION - AT sensor. Apply sealer or equivalent to Threads only. - Tighten the IAT sensor to the specified torque. Torque 30 Nm (22 lb-ft) - Wiring connector Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation KS Circuit PURPOSE Provides a signal to the ECM when engine detonation occurs. LOCATION Knock sensor is mounted in engine block under intake manifold. The solid state module is near the upper R.H. corner of the inner fender. OPERATION When abnormal engine vibrations (spark knock) are present, sensor produces voltage signal which is received by knock sensor (KS) module. As long as KS module sees no voltage from knock sensor, KS sends a signal voltage (8 to 10 volts) to ECM which in turn provides normal spark advance. When the sensor detects a knock is generates voltage. When the KS module receives this voltage it reduce the signal to the ECM to O volts. The ECM then retards the ignition timing. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 1510 Manifold Absolute Pressure Sensor: Description and Operation MAP Sensor PURPOSE Measures pressure in the intake manifold. LOCATION On the common chamber. OPERATION The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this to a voltage output. A closed throttle on engine coast down would produce a relatively low MAP output, while a Wide Open Throttle would produce a high output. MAP is the OPPOSITE of what would be measured on a vacuum gage. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under contain conditions, which allows the ECM to automatically adjust for different altitudes. The ECM sends a 5 volts reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A failure in the MAP sensor circuit should set a DTC 33. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 1511 Manifold Absolute Pressure Sensor: Service and Repair MAP Sensor REMOVE OR DISCONNECT - Battery negative cable. - Vacuum hose - Electrical connector - Attaching screws - Sensor INSTALL OR CONNECT - Sensor - Attaching screws - Electrical connector - Vacuum hose - Battery negative cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications Oxygen Sensor: Electrical Specifications Normal voltage range .......................................................................................................................... ................................................................... 0.1 - 1.0V Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications > Page 1516 Oxygen Sensor: Mechanical Specifications Torque ................................................................................................................................................. ......................................................... 45 Nm (33 ft lb) Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1519 Oxygen Sensor: Fuse and Fusible Link Locations Component Location - SOHC In underhood fuse/relay panel. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1520 Oxygen Sensor: Description and Operation HO2S PURPOSE The oxygen (O2) sensor measures the oxygen content of the exhaust. The ECM monitors the sensor to maintain air/fuel mixture of 14.7 to 1. LOCATION In the exhaust pipe, under the vehicle. OPERATION The oxygen sensor monitors atmospheric air versus exhaust gas oxygen content to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9 volt (low oxygen-rich mixture). By monitoring the oxygen sensor output voltage, the computer can determine the amount of oxygen in the exhaust gas and adjust the air/fuel mixture accordingly, this is known as "CLOSED LOOP" operation. When the sensor is cold it is like an open circuit and produces no voltage below 600°F (315°C). An open sensor circuit or cold sensor causes "OPEN LOOP" operation. The heated oxygen sensor works in the same manner as the non-heated oxygen sensor. The exception is that B+ is supplied to a heating unit that is part of the sensor itself. This heater receives voltage from the generator charging circuit. The heater helps the ECM control the fuel injection sooner for better fuel emissions. There are no malfunction Codes to detect if the heater part of the sensor is working. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) O2 Sensor REMOVE OR DISCONNECT Caution: ^ The Heated Oxygen Sensor (HO2S) uses a permanently attached pigtail and connector. This pigtail should not be removed from the HO2S. Damage or removal of the pigtail or connector could affect proper operation of the HO2S. ^ Take care when handling the HO2S. The in-line electrical connector and louver end must be kept free of grease, dirt, or other contaminants. Also, avoid using cleaning solvents of any type. Do not drop or roughly handle the HO2S. - Battery negative cable. - HO2S wiring connector. - HO2S NOTE: ^ The HO2S may be difficult to remove when engine temperature is below 45° C (120° F). ^ Excessive force may damage threads in exhaust pipe. INSTALL OR CONNECT - HO2S NOTE: ^ A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite which will burn away, but the glass beads will remain, making the sensor easier to remove. ^ New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason it is to be reinstalled, the threads must have antiseize compound applied before reinstallation. ^ Apply anti-seize compound or equivalent to threads of oxygen sensor if necessary. - Tighten the oxygen sensor to the specified torque. Torque 55 N-m (40 lb-ft) - HO2S wiring connector. - Battery negative cable. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 1523 Oxygen Sensor: Service and Repair Oxygen Sensor Life Indicator Light OXYGEN SENSOR LIFE INDICATOR LIGHT (O2) RESET PROCEDURE At 90,000 mile intervals, the O2 sensor lamp will illuminate. After replacing the sensor, perform the following procedure to reset the lamp. Maintainence Reminder Light Reset - Remove instrument cluster. - Remove masking tape from hole B. - Remove screw from hole A and install into hole B. - Apply new masking tape to hole A. - Install instrument cluster. NOTE: This procedure assumes that the sensor is being replaced for the first time (at 90,000 miles). For subsequent reset procedure (every 90,000 miles), hole positions will be the opposite of this procedure. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Pressure .............................................................................................................................................. ..................................................... Switch Condition Low pressure ....................................................................................................................................... ........................................................................... open High pressure ................................................. ........................................................................................................................................................ continuity Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1527 Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1528 Power Steering Pressure Switch: Description and Operation PURPOSE Provides the ECM with power steering load information. LOCATION In the pressure line, near the radiator. OPERATION The Power Steering Pressure Switch tells ECM vehicle is in parking maneuver. ECM will compensate for additional engine load by adjusting idle air control valve and switching OFF A/C compressor when high pressures are detected. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position ................................................................................................................................... ...................................... Signal Voltage To ECM At idle ................................................................................................................................................... ......................................................... less than 1.25V At WOT ............................................................ ................................................................................................................................................ approx. 4.5V Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1532 Throttle Position Sensor: Locations Idle Air Control (IAC) Valve On the throttle chamber. Isuzu Trooper (2 Door) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993)) Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1533 Throttle Position Sensor: Description and Operation Throttle Position Sensor TPS PURPOSE Informs the ECM with throttle valve position information. LOCATION On the throttle chamber. OPERATION The Throttle Position Sensor (TP) is a potentiometer connected to the throttle shaft on the throttle body assembly. TPS electrical circuit consists of a 5 volt supply line and a ground line, both provided by ECM. By monitoring voltage on this signal line, ECM calculates throttle position. As throttle valve position is changed, output o