1998 ISUZU TROOPER service

SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Troubleshooting........................................................00Ð 3
Main Data and Specifications.............................................00Ð45
Fixing Torque...........................................................00Ð48
Special Tools...........................................................00Ð52
SERVICE INFORMATION 00 Ð 1

00 Ð 2 SERVICE INFORMATION
MEMO

SERVICE INFORMATION 00 Ð 3
TROUBLESHOOTING
CONTENTS
PAGE
Circuit Diagram.........................................................00Ð 4
Heating Cycle Troubleshooting............................................00Ð16
Fan Control Knob (Fan Switch)............................................00Ð17
Blower Motor Does Not Run............................................00Ð18
Blower Motor Does Not Run In Certain Position............................00Ð19
Blower Motor Does Not Stop at ÒOFFÓ Position............................00Ð19
Ceramic Heater.........................................................00Ð20
Ceramic Heater Does Not Operate.......................................00Ð21
Ceramic Heater Does Not Stop..........................................00Ð22
Air Conditioning Cycle Troubleshooting.....................................00Ð23
Checking Refrigerant System with Manifold Gauge.........................00Ð24
Magnetic Clutch........................................................00Ð27
6VD1/6VE1 Engine....................................................00Ð27
4JG2 Engine.........................................................00Ð31
4JX1 Engine..........................................................00Ð34
Condenser Fan..........................................................00Ð37
Condenser Fan Does Not Run...........................................00Ð38
Condenser Fan Does Not Stop..........................................00Ð39
Compressor Troubleshooting.............................................00Ð40
Individual Inspection.....................................................00Ð41

00 Ð 4 SERVICE INFORMATION
CIRCUIT DIAGRAM
6VD1/6VE1 (RHD)
0.5 LG
0.5 LG
B -1 BODY-RH
BODY-LH
FRAME
ENG.5B
BODY
8B / R
8 B
+
_
P - 6
30B
P - 1
P - 5
P - 10
P - 7
P - 2
FL-1
80A MAINFL-4
30A CONDENSER FAN
F-6
15A RR COOLER
I-232
I-236 A/C SW
BLOWER
MOTOR
0.3 G/Y
I-42 I-42
I-421 3
216
0.5 LG
1
5W
B-190.5 BR
0.5 BR
0.5 P/G H-24 H-5113 1
H-167
H-16
2 L/R
I-41
I-18
I-18
I-18
I-18 1.25 L/O
1.25 L/Y
0.85 L/W 3
36
5
2 4
1 6
FAN SW HEATER BEZEL
ILLUMINATION
I-23 I-23
I-18
I-183
5
4
10.3 R/G0.85 G/R
ILLUMINATION
CONTROLLER (3) RELAY ; TAIL (4)
H-201
2 B
2BLOWER
RESISTOR
I-41
I-41
I-41
I-41
2L/B
2 B
1.25B
M
B-52
1B-5
B-361
B-36
B-36 B-362
34
I-23
10.85W/G
3L/R 3LC-19
25A BLOWER
0.3B
ELECTRONIC
THERMOSTAT
5W 3W
0.5 BR
1.25 L/O
0.5 LG/Y
0.3 G/Y 0.3 G/Y RELAY ;
HEATER AND
A/C
C-20 10A
AIR CON.
0.5 BR 0.5 BR
RELAY;STARTER (1)
5W
H-14
16
H-26
2L/B
2
H-20
H-1310
0.3 G/Y
0.5 LG
D08RY00128

SERVICE INFORMATION 00 Ð 5
D08RY00129
0.5 LG
X - 5 X - 5
X - 5 X - 5
14 RELAY ;
A/C THERMO320.5 P/G
0.3 G/Y
1.25 BX - 7 X - 7
X - 7 X - 7
43 21
H - 417H - 415
H - 69
E - 31
0.5BR/Y 0.5BR/Y
0.5G/B 0.5G/B 0.5BR/Y
0.5 BR
PCM (E15)
PCM (B14)0.5 G/O
0.5
G/W 0.5
G/W0.5
G/W
RELAY;
A/C COMPRESSOR MAGNETIC CLUTCH
0.5 LG
0.5 BR
C - 25 C - 25PRESSURE SW
(CONDENSER)
2H-4112
C - 39 FENDER-RH
1 1
H-51
6H-15
1
1
H-31
2
H-50 7
C-39
0.5 LG/Y 0.5 BR0.5 BR 0.5 BR
0.5 BR 0.5 LG
0.5B
0.5B 3 B 0.5LG/B0.5LG/B 0.5LG/B
R - 3
BODY-RR
X - 6 X - 6
X - 6
H-50
RR COOLER
CONNECTOR X - 6
RELAY ; RR COOLER
12
X-19X-19
53 34
C-25
3
TRIPLE SW
4
H-51
0.5 W/G3
H-42
0.5 W/G2
0.5 W/G4
X-191
X-19
C-75
1.25L
1
H - 163
0.3G/Y
M
2C-75
1.25B
(IF EQUIPPED)
RELAY; CONDENSER FAN CONDENSER FAN
1.25 L/O
C-25
H-416 4
H-512

00 Ð 6 SERVICE INFORMATION
6VD1/6VE1-(LHD)
0.5 LG
H - 2614
B - 2 BODY-LH
BODY-RH
FRAME
ENG.5B
BODY
8B / R
8 B
+
_
P - 6
30B
P - 1
P - 5
P - 10
P - 7
P - 2
FL-1
80A MAIN
I - 232
I - 23
I - 236
1A/C SW
BLOWER
MOTOR
0.3 G/Y
I-42 I-42
I-421 3
221 0.5LG
H-141
5W
B-190.5 BR
B
OFF ST
IG2
ACCSTARTER SWIG1
B2 1
4
2
5WFL-2
50A KEY SW
H-142
3W/B
B-11
0.5 BR
0.5 P/G H - 9
H - 51 19 1
H-1617
H-16 0.5LG
0.5 LG
0.5 LG
0.3G/Y
2 L/R
I-41
I - 18
I - 18
I - 18
I - 18 1.25 L/O
1.25 L/Y
0.85 L/W 3
36
5
2 4
1 6
FAN SW HEATER BEZEL
ILLUMINATION
I - 23 I - 23
I - 18
I - 183
5
4
10.5 R/G0.85 G/R
ILLUMINATION
CONTROLLER (3) FUSE F-12
H - 4815
2 B
2BLOWER
RESISTOR
I-41
I-41
I-41
I-41
2L/B
2 B
0.3G/Y
1.25B
M
B - 51
2
C-11 10A
AUDIO(ACC),MIRROR
B - 5
B-361
B-36
B-36 B-362
34
3L/B
0.5O/G
3L/R 3LC-19
25A BLOWER
0.5B
ELECTRONIC
THERMOSTAT
5W 3W
3W/B
3W/B
0.3 G/Y
1
RELAY ;
HEATER AND
A/C
C-20 10A
AIR CON.
0.5 BR
0.5 BR
B - 11B - 11
FL-4
30A CONDENSER FAN
F-1
15A RR COOLER1.25 L/O
0.5LG/Y
0.3 G/Y
D08RY00130

SERVICE INFORMATION 00 Ð 7
D08RY00131
0.5BR/Y
5
0.5BR/Y
H - 415
H-15
1
1
H-31
2
H-50 7
C-39
X - 5 X - 5
X - 5 X - 5
14 RELAY ;
A/C THERMO32
H-416 0.5 P/G
0.5 BR 0.5 G/O
0.5 BR
0.5 LG/Y 0.5 BR
0.5 BR
0.5 BR
X - 7 X - 7
X - 7 X - 7
43 21
H - 417
H - 69
E - 31
0.5BR/Y
0.5G/B
0.5B
0.5B 3 B 0.5LG/B0.5LG/B 0.5LG/B
R - 3
BODY-RR
PCM (B14)
PCM (E15)
X - 6 X - 6
X - 6
H-50
RR COOLER
CONNECTOR X - 6
RELAY ; RR COOLER
12
RELAY;
A/C COMPRESSOR MAGNETIC CLUTCH
0.5G/W
0.5G/W
0.5G/W
H-51
0.5 BR
C - 25 C - 25DUAL PRESSURE SW
or
TRIPLE SW
2H-4112 1H-514
X-19X-19
53 34
C-25
3
TRIPLE SW
4
H-51
0.5 W/R3
H-42
0.5 W/R2
0.5 W/R4
X-191
X-19
C-75
1.25L
1
H - 1217
0.3G/Y
M
2C-75
1.25B
(IF EQUIPPED)
RELAY; CONDENSER FAN CONDENSER FAN
1.25 L/O
C-25
C-39 FENDER-RH2
0.3 G/Y
0.5 LG 0.5 LG2

00 Ð 8 SERVICE INFORMATION
4JG2 (RHD)
C-69
FENDER-LHB-1 BODY-RH
BODY-LH
FRAME
ENG.5B
BODY
8B / R
8 B
+
_
P - 6
30B
P - 1
P - 5
P - 10
P - 7
P - 2
FL-1
80A MAINFL-4 30A
CONDENSER FAN
F-6 10A
RR COOLER
1
2 I-232
I-23
I-236
1A/C SW
BLOWER
MOTOR
0.5G/O
I-42 I-42
I-421 3
216
0.5
G/W 0.5 LG
C-25
C-25
0.5LGH-141
5W
B-190.5 BR
0.5BR
X-5 X-5
X-5 X-5
34 RELAY ;
A/C THERMO1
2
0.5 P/G 0.5 P/G
H-41100.5
G/W0.5
G/W
0.5 BR0.5
BR0.5
LG
PRESSURE SW
(CONDENSER) H-2413
0.5 LG
H-16 0.5LG
0.3GY
H-416
H-51
E-31
0.5 G/O
2L/R
I-41
I-18
I-18
I-18
I-18 1.25L/O
1.25L/Y
0.85L/W 3
36
5
2 4
1 6
FAN SW HEATER BEZEL
ILLUMINATION
I-23 I-23
I-18
I-18 3
5
4
10.3 R/G0.85 G/R
ILLUMINATION
CONTROLLER (3)RELAY ; TAIL (4)
H-201 2
BLOWER
RESISTOR
I-41
I-41
I-41
I-41
2L/B
2 B
1.25B
M
B-52
1B-5
B-361
B-36
B-36 B-362
34
3L/R 3LC-19
25A BLOWERRELAY ;
HEATER AND
A/C
0.3B
ELECTRONIC
THERMOSTAT
MAGNETIC CLUTCH
0.5G/O
5W 3W
0.5 BR 1.25 L/O
0.5 LG/Y
2B
C-20 10A
AIR CON.
0.5BR
7H-16
0.3G/Y
0.3G/Y0.3G/Y5W
0.85W/G
RELAY ; CHARGE (1)
H-1310
2
H-202L/B
VSV; FICD
C-69
2 1
0.5G/O 0.5 G/O
C-167
0.5 B
H-2616
H-514
H-511
D08RY00124