1997-2004 Isuzu SUV Service & Repair Manual

WORKSHOP MANUAL 1999 Trooper (UX) Rodeo (UE) Amigo (UA) Vehicross (VX) 2000 Trooper (UX) Rodeo (UE) Amigo (UA) Vehicross (VX) 2001 Rodeo (UE) Rodeo Sport (UA) 2002 Axiom (UP) Trooper (UX) Rodeo (UE) Rodeo Sport (UA)

WORKSHOP MANUAL RODEO (UE) FOREWORD This manual includes special notes, important points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of vehicle components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without notice. Arrangement of the material is shown in the table of contents on the right-hand side of this page. A black spot on the first page of each section can be seen on the edge of the book below each section title. These point to a more detailed table of contents preceding each section. This manual applies to 1999 models. SECTION TABLE OF CONTENTS GENERAL INFORMATION 0A General Information 0B Maintenance and Lubrication HEATING, VENTILATION AND AIR CONDITIONING 1A HVAC System STEERING 2A Power-Assisted System SUSPENSION 3C Front Suspension 3D Rear Suspension 3E Wheel and Tire System DRIVELINE/AXLE 4A1 Differential 4A2 Differential 4B Driveline Control System 4C Drive Shaft System 4D Transfer Case BRAKE 5A Brake Control System 5B Anti-Lock Brake System 5C Power-Assisted Brake System 5D1 Parking Brake System (4x4 model) 5D2 Parking Brake System (4x2 model) HEC ENGINE 6A Engine Mechanical 6B Engine Cooling 6C Engine Fuel 6D1 Engine Electrical 6D2 Ignition System 6D3 Starting and Charging System 6E Driveability and Emissions 6F Engine Exhaust 6G Engine Lubrication 6H Engine Speed Control System 6J Induction TRANSMISSION 7A Automatic Transmission 7A1 Transmission Control System 7B Manual Transmission 7C Clutch BODY AND ACCESSORIES 8A Lighting System 8B Wiper/Washer System 8C Entertainment 8D Wiring System 8E Meter and Gauge 8F Body Structure 8G Seats 8H Security and Locks 8I Sun Roof/Convertible Top 8J Exterior/Interior Trim RESTRAINTS 9A Seat Belt System 9J Supplemental Restraint System (Air Bag System) 9J1 Restraint Control System CONTROL SYSTEM 10A Cruise Control System 6VD1 6A 6B 6C 6D1 6D2 6D3 6E 6F 6G 6H 6J

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

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

0A–3 GENERAL INFORMATION Identification Vehicle Identification Number (VIN) This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle. 710RW003 F00RX002

0A–4 GENERAL INFORMATION Engine Serial Number D 6VD1 Engine The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter. F06RW001 D X22SE Engine The gasoline engine serial number is stamped on the rear end raised area of the cylinder block left side. 035RW022 Transmission Serial Number Manual : Stamped on the left side of the transmission intermediate plate. 220RS025 Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode switch. 240RW019

0A–5 GENERAL INFORMATION Theft Prevention Standard The 11 major components listed below will be marked with 17 digit VIN at the stage of production. In addition its service parts will be marked with manufacturer’s trade mark, “R” mark and “DOT” mark. Reference COMPONENT INDICATION Figure No. COMPONENT PRODUCTION SERVICE PARTS 0A-10 ENGINE 1– 6VD1 – X22SE VIN plate 0A-11 TRANSMISSION 2– Manual transmission – Automatic transmission VIN plate 0A-11 BODY 3– Engine hood 4– Front door 5– Rear door 6– Fender 7– Rear Quarter panel 8– Front bumper 9– Back door left side 10– Back door right side 11– Rear bumper VIN label Anti Theft Stamping/Plate/Label STAMPING/PLATE LABEL PRODUCTION SERVICE PARTS

0A–6 GENERAL INFORMATION Anti Theft Stamping/Label/Plate Location The stamping, label and plate locations are indicated by arrows in the illustration below. NOTE: 1. VIN plate locations for production. 2. Stamping locations for service parts. Engine (6VD1) 901RW080 Engine (X22SE) 035RW025

0A–7 GENERAL INFORMATION Manual Transmission (TREMEC T5) 240RW020 Manual Transmission (MUA) 901RW081

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1997-2004 Isuzu SUV Service & Repair Manual

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