Isuzu Trooper II 1991–2002 Workshop Manual
Welcome to the page dedicated to the complete factory repair and maintenance manual for the second generation Isuzu Trooper II (1991–2002). This manual covers all aspects of maintenance, diagnostics, adjustments and major repairs of one of the most reliable Japanese SUVs of the 90s.
3.2L V6 6VD1 (SOHC and DOHC)
3.5L V6 6VE1 (DOHC)
3.1L diesel 4JG2
3.0L diesel 4JX1
- Detailed technical specifications
- Step-by-step repair instructions for all components
- Wiring and electrical equipment diagrams
- Fault diagnostics (including OBD-II error codes)
- Original assembly/disassembly procedures from the manufacturer
- Illustrations, diagrams and tolerance tables
Password for PDF: www.auto-manual.com
Trooper II 1991–2002 General Information Download
Trooper II 1991–2002 Ventilation and Air Conditioning Download
Trooper II 1991–2002 Steering Download
Trooper II 1991–2002 Suspension Download
Trooper II 1991–2002 Driveline/Axle Download
Trooper II 1991–2002 Brakes Download
Trooper II 1991–2002 Engine Download
Trooper II 1991–2002 Transmission Download
Trooper II 1991–2002 Body and Accessories Download
Trooper II 1991–2002 Restraints Download
Trooper II 1991–2002 Control System Download
Isuzu Trooper II 1991–2002 Typical Malfunctions
🔧 Engine (6VD1 / 6VE1):
Increased oil consumption (especially 6VE1 3.5L)
Causes: wear of oil scraper rings, crankcase ventilation (PCV), coking.
Consequences: smoke, sticking of rings, risk of cylinder scoring.
Leaking valve cover gaskets and timing cover
Oil leaks on exhaust manifolds, possible burning smell.
Engine overheating
Causes: clogged radiator, faulty thermostat, coolant leaks.
Vulnerable point - intake manifold (antifreeze leak).
Unstable idling
Often associated with contamination of the throttle valve or malfunction of the IACV (idle air control valve).
⚡ Electrical:
Instrument cluster malfunctions
Flashing lights, unstable speedometer/tachometer readings.
Generator malfunctions
Charging problems, in some cases short circuit of diodes.
⚙️ Transmission:
Automatic transmission (4L30-E)
Overheating, kicks, delayed shifting.
Often caused by dirty oil, clogged filter or overheating.
Transfer case (TOD – Torque on Demand)
Failures are possible due to wear of sensors or failure of the transfer case ECU.
🛞 Chassis:
Front suspension — rapid wear of ball joints and stabilizer bushings
Play and extraneous knocking are possible.
Front differential and drive seal leaks
🧊 Other:
Rear frame corrosion (especially in northern regions)
Often leads to technical inspection failure.
ABS and "Check TOD" system failures
Causes: dirt on wheel speed sensors, worn wiring.