HEATER SYSTEM

1986 Isuzu Trooper II

1986 Heater Systems

ISUZU

I-Mark, P’UP, Trooper II

DESCRIPTION
The Isuzu heater system is a system in which outside air is
forced into the heater unit assembly, heated, and then distributed
into the passenger compartment. The system consists of a blower and
air inlet assembly, heater assembly, heater control assembly and
heater valve assembly.

Fig. 1: Exploded View of I-Mark Heating System

OPERATION
 BLOWER & AIR INLET ASSEMBLY
The blower and air inlet assembly draws outside air through
the outside air inlet grille located forward of the windshield and
channels the air into the heater assembly. The operation of the
blower motor is controlled by a fan switch on the heater control.

HEATER ASSEMBLY
The heater assembly houses the heater core, diverter door
and defroster door. The heater core’s coolant flow is controlled by a
heater valve which is located on the left side of the blower motor
assembly.

MODE LEVER
Mode lever controls air flow air doors (intake, blend-air,
heat, defrost and ventilation).

TEMPERATURE LEVER
This lever sets position of blend-air door to direct flow of
air through heater core ("HOT" position), around heater core ("COLD"
position), or mixture of both (modulated temperature between full
"HOT" and full "COLD").
The lever also controls opening and closing of water valve.
In any position except "COLD", water valve is open, allowing engine
coolant into heater.

AIR SOURCE SELECTOR LEVER

The air source selector lever in one position will
recirculate interior air and in the other will obtain fresh air from
the exterior.

ROTARY KNOB
The rotary control knob has several positions which control
the desired blower motor speeds.

Fig. 2: Exploded View of Trooper II Heating System Components

ADJUSTMENTS
NOTE: Adjustments listed are for I-Mark only. Specific procedures
for heater-only equipped P’UP and Trooper models are not
available from manufacturer. For more information, see
"MANUAL A/C-HEATER SYSTEM -- ISUZU" in MANUAL A/C-HEATER
SYSTEM section.

SELECTOR LEVER
1) Position control lever at "DEF". On assist side of heater
unit (in car), set actuating mechanism at position "A". See Fig. 3.
Insert cable and install clip.
2) Check adjustment with selector lever. With mode lever in
"DEF" position and actuating mechanism in position "A", air flows
from defroster ducts. With mode lever in "FOOT" position and
actuating mechanism in position "B", air flows from heater outlet.
With mode lever in "FACE" or "BI-LEVEL" and actuating mechanism in
position "C", air flows from vent outlets. See Fig. 3.

Fig. 3: Actuating Mechanism Positions

FRESH AIR INLET DOOR

Position control lever at "CIRC". On blower unit (engine
compartment) shut fresh air inlet door. Connect cable and install
clip. Door adjustment should be completely shut in "CIRC" position.

TEMPERATURE CONTROL
Position control lever at "COLD". Position heater valve
shaft in full "COLD" position. Connect cable and install clip. Check
to make sure valve opens fully with temperature lever in "HOT"
position.

TROUBLE SHOOTING

BLOWER MOTOR INOPERATIVE

Check for burned, broken, or incorrect fuse. Check for loose
connectors or broken wires. Visually inspect resistor assembly. Check
for broken or melted coils. Test for continuity. Test for defective
blower switch.

INSUFFICIENT HEATING
Partially plugged heater core. Malfunctioning heater valve.
Improperly adjusted temperature lever cable. Test engine thermostat
for opening too soon, stuck open, or held open by foreign material.
Visually inspect radiator coolant level and add if necessary. Check
for pinched or plugged heater hose.

INADEQUATE DEFROSTING
Partially plugged heater core. Malfunctioning heater valve.
Improperly adjusted selector and/or temperature lever cable.
Mispositioned defroster outlets and/or hoses. Obstructed defroster
outlets and/or hoses. Visually inspect coolant level in radiator. Add
coolant if necessary.

REMOVAL & INSTALLATION

NOTE: The following procedures, with the exception of Rear Heater
Unit, pertain to I-Mark models only. Specific procedures for
heater-only equipped P’UP and Trooper models are not
available from manufacturer. For more information, see
"MANUAL A/C-HEATER SYSTEM -- ISUZU" in MANUAL A/C-HEATER
SYSTEM section. An exploded view of the heater unit for
P’UP and Trooper is provided for reference.

Fig. 4: Exploded View of Heater Unit P’UP and Trooper models only.
 HEATER VALVE
Removal
Remove heater hoses and plug ends to prevent foreign
material from entering. Disconnect temperature cable. Remove heater
valve.

Installation
To install, reverse removal procedure. Adjust temperature
cable so that when temperature is cold, heater valve shaft is in full
cold position. Idle engine with radiator cap off to allow any trapped
air to escape from cooling system.

BLOWER MOTOR
Removal
Disconnect battery ground cable and wiring at blower motor.
Remove retaining screws and pull out blower motor and squirrel cage.
Remove retaining clip holding squirrel cage to motor and remove
squirrel cage.

Installation
To install, reverse removal procedure.

RESISTOR ASSEMBLY
Removal
Remove dash wall (diesel model only). Disconnect battery
ground cable. Remove outer blower case cover. Disconnect resistor
wiring harness. Remove 2 attaching screws and remove resistor.

Installation
To install, reverse removal procedure.

HEATER CONTROL PANEL

Removal
1) Disconnect battery ground cable. Remove outer blower unit
case cover and disconnect fresh air door cable. Disconnect
temperature cable at heater valve.
2) Remove steering wheel. Remove instrument cluster and
heater control face plate. Disconnect selector mode cable from assist
side of heater unit assembly and remove 3 phillips screws retaining
heater control panel.
3) Carefully pull temperature and fresh air door cables
through cowl and remove control panel through cluster opening.

Installation
To install, reverse removal procedures. Adjust cables as
necessary.

BLOWER SWITCH
Disconnect battery ground cable. Remove heater control
panel. Remove blower switch from control unit. To install, reverse
removal procedure.

HEATER CORE
Removal
1) Disconnect battery ground cable and drain radiator.
Disconnect heater hoses at core connections and plug core tubes to
prevent spillage of coolant when removing heater assembly.
2) Remove outer blower unit case cover and disconnect fresh
air door cable. Disconnect temperature cable at heater valve. Remove
steering wheel. Remove instrument cluster. Disconnect wiring for
console gauges. Remove console retaining screws and untie shift lever
leather cover.
3) Remove center console, heater control and plate and glove
box. Disconnect selector mode cable from drivers side of heater unit
assembly. Carefully pull temperature and fresh air door cables
through cowl and remove control panel through cluster opening.
4) Remove instrument panel assembly. Remove heater unit
assembly through-bolt located at rear and bottom of heater unit
assembly.

Installation
To install, reverse removal procedure. Adjust heater control
cables.

REAR HEATER UNIT

NOTE: The rear heater unit is under the rear seat. The seat must
be removed prior to performing this procedure.

Removal (Trooper II Only)

Remove hose clamps fastening heater hoses to rear heater
unit. Remove bolts fastening rear heater unit to body. Disconnect
wiring harness at connectors. Remove rear heater assembly from
vehicle. To expose heater core and blower motor, remove cover
fastening screws and remove cover.

Installation
To install, reverse removal procedure.

Fig. 5: View of Rear Heater Unit

VENT CABLE
Removal & Installation
Disconnect battery ground cable. Remove heater control
panel. Remove cable from control panel. To install, reverse removal
procedure.

TEMPERATURE CABLE
Removal & Installation
Disconnect battery ground cable. Remove heater control
panel. Remove cable from heater control panel. To install, reverse
removal procedure and adjust cable.

SELECTOR LEVER CABLE

Removal & Installation
Disconnect battery ground cable. Remove heater control
panel. Remove cable from control panel. To install, reverse removal
procedure and adjust cable.

Fig. 6: Isuzu I-Mark Heater Wiring Diagram

Fig. 7: Isuzu Trooper II Heater Wiring Diagram