ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Adjustments

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THROTTLE LINKAGE



1981-87 Models
WITH GASOLINE ENGINES

See Figures 1 and 2



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Fig. Fig. 1: Adjust the throttle valve cable so there is 0.032-0.059 in. (0.8-1.5mm) clearance between the rubber boot and the cable stopper-1981-87 models with gasoline engines



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Fig. Fig. 2: Location of the throttle adjusting screw-1981-87 models with gasoline engines

  1. Open the hood and remove the air cleaner housing.
  2.  
  3. Loosen the throttle valve control cable adjusting nuts.
  4.  
  5. Check that the carburetor throttle adjusting screw is in contact with the stopper for normal idling.
  6.  

If the adjusting screw is not resting on the stopper, the fast idle mechanism is working and setting of the adjusting screw should be performed to obtain normal idling.

  1. To obtain normal idling, perform the following procedure:
    1. Disconnect the battery ground cable.
    2.  
    3. Remove the air cleaner cover, if not already done.
    4.  
    5. Fully depress and release the accelerator pedal to place the choke in the wide open position; do not depress the pedal again.
    6.  
    7. Check that the throttle adjusting screw is in contact with the stopper.
    8.  
    9. Install the air cleaner housing.
    10.  
    11. Connect the battery cable.
    12.  

  2.  
  3. Remove the rubber boot from the outer cable and turn the adjusting nuts to bring the outer cable setting to within 0.032-0.059 in. (0.8-1.5mm). Once this clearance is achieved, tighten the adjusting nuts. The proper clearance should be measured between the outer cable end and the inner cable stopper.
  4.  
  5. After adjusting the throttle cable, check that the inner cable stroke is 1.30-1.36 in. (32.9-33.9mm) from the closed position of the throttle valve to the wide open position.
  6.  
  7. Install the rubber boot onto the outer cable.
  8.  

WITH DIESEL ENGINES

See Figure 3



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Fig. Fig. 3: The throttle cable free-play should be between 0-0.04 in. (0-1mm)-Diesel engines

Normal idling position can not be obtained with the air conditioner operating and the engine coolant temperature higher than 59°F (15°C).

  1. Loosen the throttle valve control cable adjusting nuts.
  2.  
  3. Have an assistant fully depress the accelerator pedal to place the injection pump lever in contact with the maximum speed adjusting screw, then hold the lever in that position.
  4.  
  5. If the injection pump lever is not in contact with the adjusting screw, adjust the accelerator linkage.
  6.  
  7. Turn the outer cable adjusting nuts to adjust the outer cable setting to 0.032-0.059 in. (0.8-1.5mm) and tighten the adjusting nuts; the setting is the distance between the upper face of the rubber boot, on the end of the outer cable, and the inner cable stopper.
  8.  
  9. After adjusting, check that the inner cable stroke, from the normal idling position to the maximum speed position is 1.30-1.36 in. (32.9-33.9mm).
  10.  

1988-90 Models

See Figure 4



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Fig. Fig. 4: Adjust the throttle cable so there is 0.032-0.059 in. (0.8-1.5mm) between the inner cable stopper and the tip of the cable housing-1988-90 models

  1. Open the hood and remove the air cleaner housing.
  2.  
  3. Have an assistant depress the accelerator pedal all the way to the floor. Check that the throttle valve in the carburetor opens fully.
  4.  
  5. If the throttle valve does not open fully, adjust the accelerator link.
  6.  
  7. Have your assistant fully depress the accelerator pedal and hold it there during the adjustment procedure.
  8.  
  9. Loosen the adjustment nuts on the carburetor end of the throttle cable.
  10.  
  11. Adjust the cable housing so the distance between the end of the boot and stopper on the cable is the 0.03-0.06 in. (0.8-1.5mm).
  12.  
  13. Tighten the adjusting nuts until snug.
  14.  
  15. Reinspect the throttle cable adjustment.
  16.  
  17. Install the air cleaner housing, then shut the hood.
  18.  

1991-96 Models

The 1991-96 models utilize a Powertrain Control Module (PCM), which controls the idle speed and mixture settings automatically. There is no transmission-controlled throttle linkage on these vehicles and the PCM requires no adjustment.

SHIFT LINKAGE



Shift Control Cable
1981-87 PICK-UP MODELS

See Figure 5



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Fig. Fig. 5: After rotating the manual shaft fully clockwise, turn it counterclockwise to the 3rd position-1981-87 models

  1. Remove the trim panel from around the automatic shifter assembly.
  2.  
  3. Raise the vehicle and safely support the vehicle on jackstands.
  4.  
  5. From under the vehicle, loosen the control rod locknuts so the trunnion will slide on the control rod.
  6.  
  7. Turn the manual shaft on the transmission fully clockwise (viewed from the left side of the transmission), then back it off to the 3rd stop, which should be the N position.
  8.  
  9. While holding the shaft in this position, have an assistant in the vehicle move the gear shift lever to the N position.
  10.  
  11. Push the shift shaft, with the shift control lower lever rearward to remove play, then tighten the adjusting nuts.
  12.  
  13. Lower the vehicle and install all trim panels removed.
  14.  
  15. Road test the vehicle and check for proper operation of the transmission in all ranges.
  16.  

1988-95 PICK-UP, 1988-91 TROOPER AND 1992-94 AMIGO MODELS

See Figure 6



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Fig. Fig. 6: The nut on the end of the shift linkage rod is the one which should be loosened when adjusting the shift linkage

  1. Apply the parking brake and block the rear wheels.
  2.  
  3. If necessary for access under the vehicle, raise and safely support the front of the vehicle with jackstands.
  4.  
  5. Loosen the nut on the shift linkage (the nut holds the shift rod to the gear shift lower lever).
  6.  
  7. On the transmission, push the shift lever fully rearward (counterclockwise). The shift lever is mounted to the right-hand side of the transmission; do not mistake this for the gear shift selector lever, which is mounted in the vehicle's passenger compartment.
  8.  
  9. Push the shift lever, in the clockwise direction, 2 notches, which should position the lever in the N position.
  10.  
  11. Have an assistant move the gear shift selector lever in the passenger's compartment to the N position. The assistant should press the selector lever, while remaining in the N range, slightly toward the R range. With the selector lever held in this position, tighten the shift linkage nut until snug. Do not tighten it so much that it pulls the transmission shift lever out of the N position.
  12.  
  13. Lower the vehicle and remove the rear wheel blocks.
  14.  
  15. Make sure the transmission shift linkage functions correctly.
  16.  

Select Lever and Control Rod
1992-96 TROOPER AND RODEO MODELS

See Figure 7



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Fig. Fig. 7: Identification of the select lever and control rod components-make sure to hold the select lever so the pin contacts the detent plate wall (upper inset)

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the interior trim panels from around the shift selector lever in the passenger's compartment.
  4.  
  5. If necessary for access to the underside of the vehicle, apply the parking brake, block the rear wheels, raise and safely support the front of the vehicle on jackstands.
  6.  
  7. Set the select lever in the N position.
  8.  
  9. Push the select lever forward and secure it (using a rubber band or piece of string) so the pin on the lever comes into contact with the wall of the detent plate.
  10.  
  11. Turn nut (1) by hand until it comes into contact with the boss (3).
  12.  

Clean the rod threads, but do not apply oil to the threads.

  1. While holding nut (1) with a wrench or similar tool, tighten nut (2) to 20 ft. lbs. (27 Nm).
  2.  
  3. Install the clip (4) and tighten the nut (5) to 61 inch lbs. (7 Nm).
  4.  
  5. After adjustment, operate the select lever on a trial basis to make sure of its smooth operation and no abnormal indication in each transmission position.
  6.  
  7. Lower the vehicle and remove the rear wheel blocks, if necessary.
  8.  
  9. Install any interior trim panels removed earlier.
  10.  
  11. Connect the negative battery cable.
  12.  

Shift Lock Cable
1992-96 TROOPER AND RODEO MODELS

See Figure 8



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Fig. Fig. 8: The shift lock cable is adjusted on the select lever end of the cable-removal of the interior select lever trim panels is necessary for access

  1. Place the ignition switch in the LOCK position and the transmission gear selector lever in the P position.
  2.  
  3. Remove the shift lever trim piece.
  4.  
  5. Adjust the cable screw cap on the select lever side to provide a gap (slack of cable) of 0.059-0.098 in. (1.5-2.5mm) between the rod on the steering lock side and the stopper. Adjust the cap as follows:
    1. Hand turn the nut (A) until it comes in contact with the bracket while pulling the screw cap in the direction of the arrow (as in illustration) to prevent slack in the inner cable.
    2.  
    3. Loosen the nut (A) 2 revolutions to provide 0.078 in. (2mm) slack for 1992-95 models or 0.20 in. (5mm) slack for 1996 models to the inner cable.
    4.  
    5. Lock the inner cable by tightening the nut (B) to 33 inch lbs. (3.7 Nm) while holding nut (A) in place with a wrench.
    6.  

  6.  

Clean the cable threads, but do not apply oil to the threaded portions.

  1. Check the operation of the shift lever and make certain it meets the following criteria:
    1. The select lever should not be able to move out of the P position with the ignition switch in the LOCK position.
    2.  
    3. The select lever should be able to move out of the P position when the ignition switch is in the ON position only when the brake pedal is depressed.
    4.  
    5. The ignition switch should be able to be turned to the LOCK position only when the select lever is in the P position (the key can be pulled out).
    6.  

  2.  
  3. If the vehicle failed Steps 4a and 4c, readjust the shift lock cable. If the vehicle failed Step 4b, readjust the connector wiring and the brake pedal switch.
  4.  
  5. Install the shift lever trim piece.
  6.  

 
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