1986 Isuzu Trooper Diesel Manual

The 1986 Isuzu Trooper Diesel is a rugged 4x4 SUV featuring a 2.2L C223 diesel engine, 5-speed manual transmission, part-time 4WD system, and durable body-on-frame construction. This manual covers operation, maintenance, specifications, and troubleshooting for this reliable off-road vehicle known for its fuel efficiency and off-road capability.

1. Vehicle Overview 2. Specifications 3. Operation Instructions 4. Maintenance Schedule 5. Engine System 6. Transmission & Drivetrain 7. Brake System 8. Electrical System 9. Troubleshooting 10. Warranty Information

Vehicle Overview

The 1986 Isuzu Trooper Diesel combines utility and efficiency with its diesel powertrain and versatile 4WD system.

Component	Description
Engine	2.2L C223 inline-4 diesel engine
Transmission	5-speed manual transmission
Drivetrain	Part-time 4WD with 2WD/4WD selection
Fuel System	Direct injection diesel
Suspension	Independent front, live axle rear
Brakes	Front disc, rear drum with vacuum booster
Seating Capacity	5 passengers
Cargo Capacity	65 cubic feet with rear seats folded
Fuel Tank	19.8 gallons capacity
Towing Capacity	2,000 lbs maximum

Specifications

Engine: 2.2L C223 inline-4 diesel
Displacement: 2238 cc
Power Output: 80 hp @ 4300 rpm
Torque: 120 lb-ft @ 2200 rpm
Transmission: 5-speed manual
Transfer Case: 2-speed part-time 4WD
Fuel Economy: 25 mpg city / 30 mpg highway
Dimensions: 165.4" L x 65.6" W x 70.1" H
Wheelbase: 91.7 inches
Ground Clearance: 8.1 inches

Operation Instructions

Proper operation ensures longevity and optimal performance.

Starting Procedure: Turn key to ON, wait for glow plug light to extinguish, then start engine.
4WD Operation: Stop vehicle before shifting between 2WD and 4WD modes.
Gear Shifting: Use clutch fully when shifting gears; avoid riding clutch.
Cold Weather Operation: Allow extra glow plug time in temperatures below 40°F.
Off-Road Use: Engage 4WD Low range for steep inclines and rough terrain.

WARNING! Never shift into 4WD on dry pavement to avoid drivetrain damage.

Maintenance Schedule

Regular maintenance is crucial for diesel engine longevity.

Service	Interval	Procedure
Oil Change	3,000 miles	Replace engine oil and filter
Fuel Filter	15,000 miles	Replace diesel fuel filter
Air Filter	30,000 miles	Inspect and replace as needed
Coolant	30,000 miles	Drain and refill cooling system
Transmission Fluid	60,000 miles	Change manual transmission fluid
Timing Belt	60,000 miles	Inspect and replace timing belt

Engine System

The C223 diesel engine requires specific maintenance procedures.

Glow Plugs: Test resistance regularly; replace as set if one fails.
Injection System: Have injection timing checked every 30,000 miles.
Valve Adjustment: Adjust valve clearance every 15,000 miles.
Turbocharger (if equipped): Allow cool-down period after hard driving.

CAUTION! Diesel fuel is flammable; no smoking during fuel system work.

Transmission & Drivetrain

Proper drivetrain maintenance ensures reliable 4WD operation.

Transfer Case: Change fluid every 30,000 miles with SAE 80W-90 gear oil.
Differentials: Service front and rear differentials every 30,000 miles.
Clutch: Adjust free play every 6,000 miles; replace if slipping occurs.
U-Joints: Lubricate every 3,000 miles or as specified.

Brake System

Maintain braking performance with regular inspection.

Brake Pads: Inspect every 10,000 miles; replace if below 1/8"
Brake Fluid: Replace every 2 years or 24,000 miles
Brake Lines: Inspect for cracks or leaks annually
Parking Brake: Adjust cable tension as needed

Electrical System

The 12-volt electrical system requires proper maintenance.

Component	Maintenance	Specification
Battery	Check terminals and fluid level monthly	12V, 55 Ah
Alternator	Test output annually	55 Amp output
Starter	Inspect brushes every 60,000 miles	1.4 kW
Glow Plugs	Test resistance every 15,000 miles	Replace as set

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting in cold	Weak glow plugs	Test and replace glow plugs
White smoke at startup	Glow plug system failure	Check glow plug relay and controller
Loss of power	Clogged fuel filter	Replace fuel filter; bleed air from system
4WD won't engage	Vacuum system issue	Check vacuum lines and actuator
Transmission noise	Low fluid level	Check and fill transmission fluid

Service: Contact authorized Isuzu service center for major repairs.

Warranty Information

1986 Isuzu Trooper Diesel comes with 12-month/12,000-mile basic warranty and 5-year/60,000-mile powertrain warranty. Keep maintenance records for warranty claims. For service, contact Isuzu dealership or customer service at 1-800-255-6727.