Isuzu Trooper UBS 1999–2002 Workshop Manual Collection (P/N RV99_02-01.E)

The year modules cover whole-vehicle workshop work. The immobilizer guide adds Tech 2 programming information and no-start diagnosis to the vehicle repair sections.

The separately identified 4JX1 publication applies to vehicles outside the USA and Canada. There is no separate 2001 workshop module.

Searchable Sections and PDF Navigation

Text search and diagram detail: Most sections contain searchable text, but much of the MUA transmission material and the immobilizer guide cannot be searched. Embedded bookmarks provide navigation through all three year modules. Small wiring labels require zooming; some diagrams are arranged sideways.

The collection is supplied as one printable, 11,798-page PDF, including 2 shared cover/selector pages and 38 module-index pages.

Engine Overhaul, 4WD Service, and Electrical Diagnosis

The following is a selection of covered work, rather than a complete contents list. Other topics include wiper/washer service and entertainment-system circuits.

• Engine repair: Engine removal, cylinder-head work, timing service, internal inspection, and reassembly for the covered gasoline and diesel configurations.

• Transmissions and 4WD: Automatic and manual transmission repair, clutch service, differential overhaul, Shift-on-the-Fly and TOD diagnosis, and standard/TOD transfer cases.

• Steering, suspension, and brakes: Wheel alignment, power-steering tests and bleeding, steering-gear repair, suspension inspection, ABS diagnosis, hydraulic brake service, and parking-brake adjustment.

• Climate control: Manual and automatic A/C diagnosis, refrigerant recovery and charging, sensor and actuator checks, and compressor bench repair.

• Electrical and body systems: Wiring diagrams, connector locations, SRS service, lighting, instruments, locks, seats, sunroof or convertible-top systems, and cruise-control diagnosis.

• Maintenance and specifications: Standard and severe-use schedules, torque tables, fluid capacities, wear limits, clearances, electrical test data, and factory special-tool references.

Its bench-overhaul procedures and Tech 2 diagnostics make this collection suited to professional technicians and experienced owners with appropriate workshop equipment; immobilizer programming assumes trained service personnel.

Gasoline and Diesel Engine Repair

Gasoline-engine sections address cylinder heads and valve gear, camshafts, crankshaft and main bearings, pistons and connecting rods, lubrication, cooling, fuel delivery, ignition, starting and charging, and driveability faults.

Diesel material includes the 4JG2-NA and 4JG2-TURBO. The 4JX1 chapters extend to turbocharger service, timing gears, valve-clearance adjustment, oil-rail and injector work, engine-speed control, and electronic diagnosis.

The 2002 module separates 6VE1 8-bit and 32-bit control-system material. Step-by-step procedures cover major work such as cylinder-head removal and installation, internal engine inspection, and component reassembly.

Transmission, Transfer Case, and Axle Work

The automatic-transmission chapters combine DTC diagnosis, stall and line-pressure tests, road-test references, and internal repair. AW30-40LE coverage reaches valve-body service, major-component disassembly, individual clutch-pack inspection, and final reassembly.

AR-5 and MUA manual-transmission sections cover removal, disassembly, inspection, and assembly. MUA material distinguishes MUA 5C and MUA 5S transmissions in 4x2 and 4x4 configurations.

Axle and transfer-case chapters include 220 mm and 244 mm rear differentials, limited-slip units, pinion setup, propeller shafts, TOD clutch packs, shift-control shafts, and front-axle vacuum and electrical controls.

Steering, Suspension, and Brake Diagnosis

Alignment instructions address caster, camber, toe, trim height, and steering angle. Steering repair extends to pressure testing, flushing, bleeding, the column, linkage, pump, and steering gear.

Suspension procedures cover control arms, ball joints, torsion bars, coil springs, trailing links, and stabilizers. Brake diagnosis includes the EHCU, wheel-speed and G-sensors, master cylinder, booster, calipers, drum brakes, and hydraulic bleeding.

Wiring References and Immobilizer Service

Diagnostic references include the TOD Circuit Diagram and Basic Diagnostic Flow Chart, RHD ABS circuits for 4JX1 and 6VE1 configurations, and AW30-40LE control-system and wiring diagrams.

Fuse Block Circuits, Cable Harness Routing, and SRS Component and Wiring Location Views support circuit tracing and component identification.

The immobilizer guide covers transponder programming, ICU/ECM programming and reset functions, connector assignments, and no-start troubleshooting. It identifies Tech 2 with suitable software and the vehicle’s Car Pass information as requirements for programming work.

Automatic Climate Control and Compressor Repair

The full-automatic A/C section contains a 12-page circuit-diagram sequence, block diagrams, and separate checks for in-car, ambient, and sun sensors; intake, mix, and mode actuators; fan control; and magnetic-clutch circuits.

Its self-diagnosis routines and failed-location charts help narrow a climate-control complaint to the relevant sensor, actuator, power-supply, or wiring checks before repair work is selected.

On-vehicle procedures cover the compressor, condenser and fan, receiver/drier, pressure switches, evaporator, expansion valve, refrigerant lines, electronic thermostat, and rear cooler. DKV-14D, DKS-15CH, and HD6 bench-service material adds model-specific disassembly, inspection, clutch and shaft-seal work, reassembly, and service limits.

Special Tools and Repair Cautions

Tool references include the ACR4 refrigerant service unit 5-8840-0629-0 / J-39500-A, pinion-flange holder 5-8840-2157-0, and pinion oil-seal installer 9-8522-1275-0.

Compressor oil is model-specific; using or mixing the wrong oil can impair lubrication and seize the compressor. The cooling chapter also warns that incompatible 6VE1 and earlier 6VD1 fan arrangements can reverse airflow, reduce A/C performance, and raise coolant temperature.

The A/C procedures require refrigerant recovery before opening the circuit. SRS service precautions apply before work near airbag components or related wiring.

4JX1 Thermostat Data: A Specification Preview

For 4JX1 engine-cooling inspection, the service-standard table specifies a thermostat opening temperature of 83–87°C and valve lift of more than 9.5 mm at 100°C.