1990 ISUZU AMIGO Service and Repair Manual

Contents Introductory pages About this manual Introduction to the Isuzu Rodeo, Amigo and Honda Passport Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants Conversion factors Safety first! Fraction/decimal/millimeter equivalents Troubleshooting Chapter 1 Tune-up and routine maintenance Chapter 2 Part A 2.3L and 2.6L four cylinder engines Chapter 2 Part B 2.2L four-cylinder engine Chapter 2 Part C 3.1 LV6 engine Chapter 2 Part D 3.2LV6 engine Chapter 2 Part E General engine overhaul procedures Chapter 3 Cooling, heating and air conditioning systems Chapter 4 Part A Fuel and exhaust systems - carbureted engines Chapter 4 Part B Fuel and exhaust systems - fuel-injected engines Chapter 5 Engine electrical systems Chapter 6 Emissions and engine control systems Chapter 7 Part A Manual transmission Chapter 7 Part B Automatic transmission Chapter 7 Part C Transfer case Chapter 8 Clutch and driveline Chapter 9 Brakes Chapter 10 Suspension and steering systems Chapter 1 1 Body Chapter 12 Chassis electrical system Wiring diagrams 0-5 0-5 0-6 0-7 0-8 0-14 0-15 0-16 0-17 0-18 0-19 0-20 1-1 2A-1 2B-1 2C-1 2D-1 2E-1 3-1 4A-1 4B-1 5-1 6-1 7A-1 7B-1 7C-1 8-1 9-1 10-1 11-1 12-1 12-19 Index

0-5 About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arrang- ing an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself. Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sec- tions, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Sec- tion you will be referred to any illustrations which apply to the procedures in that Sec- tion. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it's necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word "Chapter" apply to Sections and/or paragraphs in the same Chapter. For example, "see Section 8" means in the same Chapter. References to the left or right side of the vehicle assume you are sitting in the driver's seat, facing forward. Even though we have prepared this manual with extreme care, neither the pub- lisher nor the author can accept responsibility for any errors in, or omissions from, the information given. NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand. CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on. WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury. Introduction to the Isuzu Rodeo, Amigo and the Honda Passport Isuzu Rodeo and the Honda Passport models are available in four-door station wagon body styles. The Isuzu Amigo is available in two door body style only. Early four-cylinder engines are equipped with a carburetor. Later four-cylinder engines and 3.1L V6 engines are equipped with fuel injection. All 2.2L four-cylinder and 3.2L V6 engines are equipped with multi-port fuel injection systems. The engine drives the rear wheels through either a four or five-speed manual or four-speed automatic transmission via a driveshaft and solid rear axle. A transfer case and driveshaft are used to drive the front driveaxles on 4WD models. The suspension features independent control arms, torsion bars and shock absorbers at the front. A solid axle at the rear is suspended by leaf springs or coil springs and shock absorbers. The steering box is mounted to the left of the engine and is connected to the steering arms through a series of rods. 1998 and later models are equipped with rack-and-pin- ion steering. Power assist is optional on some models. The brakes are disc at the front and drums at the rear, with power assist standard. Some later models are equipped with disc brakes in the rear, instead of drums.

mm 0-6 Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufactur- ing. Since spare parts manuals and lists are compiled vehicle nu|mbers identify th' a numerical basis, the individual are essential to correctly component required. Vehicle Identification Number (VIN) This very important identification number is stamped on a plate attached to the left side of the dashboard just inside the windshield on the driver's side of the vehicle (see illustration). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was manufactured, the model year and the body style. Engine identification number The engine ID number on four-cylinder engines is located on a machined surface on the left rear corner of the block, near the bottom. On V6 engines, the ID number is located on a pad on the left side of the block (see illustration). The Vehicle Identification Number (VIN) is visible through the driver's side of the windshield iu i UK3 L i I/ , 4S2CM58V2V4301095 UCS7VF AI/JG RLU TRANS. RMQ RBA TIRE 9VV ER8 V . I. N . M . D . ENGINE GRADE BODY TYPE VAW B. COLOR/TRIM OPTION EY1 DH6 C6O TU.1 86M 7LJ 6KC The Engine Identification Number is stamped on the left side of the engine block The Service parts and paint code label is affixed to the engine compartment firewall

Vehicle identification numbers 0-7 MANUFACTURED BY ISUZU MOTORS LIMITED AUG.96 GVWR:Z?/'OKGC'>OOOLBS> GAWR: FRONT-1065KG (2350LBS) WITH P?25/75R16 TIRES & 16X6 RIMS AT ?OOKPA (?9PSI ) COl D. GAWR:RFAR-1290KG <?8SOl. BS> WITH P225/i">R16 TIRES 8 16X6 RIMS AT ??OKPA ( 3?PS I ) COl D . THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL j MOTOR VEHICLE SAFETY AND THEFT PREVENTION STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. 4S2CM58V2V4301095 MPV SEMBLEO BY SUBARU-ISUZU J1OTIVE INC The Manufacturer's Certification label is affixed to the drivers side door end or post -DT IMPORTANT VEHICLE INFORMATION CATALYS ISUZU MOTORS LIMITED isuzu v.M; v vs/^^Avvf* JM&MLMOMJMiRlM. -.: : , A •'.'>•,? '•'*.* {. U) ','•• ? I \' ^'^ _..„ '.• : 'jl ! JP SP: CiMs;An()N;> AMD ^ .iv v^:' «.*• N''rs \ • 1/1 :., C»LIFHmil« SHMMRD CUUSOR* ."HEfl. -*M.. S J**!.M?!,"!. ,1! PIBKIHG B8»« . The Vehicle Emissions Control Information (VECI) label is located on the bottom side of the hood Service parts and paint code identification plate This plate is located in the engine compartment, usually on the firewall. It tells what options the vehicle came equipped with and the color and type of paint which was origi- nally applied to the vehicle (see illustration). Manufacturer Certification label The Manufacturer Certification label is affixed to the left front door pillar. The plate contains the name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR) and the certification statement (see illustration). Vehicle Emissions Control Information (VECI) label The emissions control information label is found under the hood. This label contains information on the emissions control equip- ment installed on the vehicle, as well as tune- up specifications (see illustration). Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned parts on an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, fil- ters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general accessories, have convenient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: If the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

0-8 Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual. Appli- cation of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the var- ious tasks properly, which will ensure that the repair job is thorough and complete. Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should be treated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use tur- pentine in a spout-type oil can, which works quite well. After applying the rust penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose. Most autof lotive this task, such as tl have been Flat machine shops can perform s well as other repair procedures, ie repair of threaded holes that stripped out. Dashers and lockwashers, when removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic. Grade 1 or 2 Grade 5 9 Grade 8 Bolt strength marking (standard/SAE/USS; bottom - metric) 3 Dots Grade Identification Hex Nut Grade 5 Hex Nut Grade 8 6 Dots Standard hex nut strength markings Grade Identification Hex Nut Property Class 9 Hex Nut Property Class 10 Arabic 9 Arabic 10 Class 9.8 Class 8.8 Metric hex nut strength markings Metric stud strength markings f 00-1 HAYNES

1990 ISUZU AMIGO Service and Repair Manual

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