Remove engine ISUZU TROOPER 1998 Service Manual PDF

6A±27
ENGINE MECHANICAL
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
nuts then disconnect exhaust front pipe.
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
4. Remove heat protector two fixing bolts then the heat
protector.
5. Remove exhaust gas recirculation (EGR) pipe fixing
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.
056RW001
Legend
(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe
6. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
Torque : 57 N´m (5.8 Kg´m/42 lb ft)
2. Install the EGR pipe, tighten bolt and nut on exhaust
manifold to specified torque.
Torque : 28 N´m (2.9 Kg´m/21 lb ft)
Tighten nut to EGR valve to the specified torque.
Torque : 44 N´m (4.5 Kg´m/33 lb ft)
Tighten the bolt for EGR pipe bracket to specified
torque.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque:
Stud nuts: 67 N´m (6.8 Kg´m/49 lb ft)
Nuts: 43 N´m (4.4 Kg´m/32 lb ft)
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.

6A±28
ENGINE MECHANICAL
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 N´m (17.0 Kg´m/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 N´m (2.2 Kg´m/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 N´m (1.0 Kg´m/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

6A±29
ENGINE MECHANICAL
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5±8840±0133±0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.

6A±32
ENGINE MECHANICAL
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
3. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley clockwise by two turns.
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 N´m (1.9 Kg´m/14 lb ft)
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using 5±8840±0133±0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
Torque : 167 N´m (17.0 Kg´m/123 lb ft)
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
Torque : 22 N´m (2.2 Kg´m/16 lb ft)
6. Install power steering pump assembly and tighten to
the specified torque.
Torque :
M8 bolt : 22 N´m (2.2 Kg´m/16 lb ft)
M10 bolt : 46 N´m (4.7 Kg´m/34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 N´m (2.2 Kg´m/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 N´m (1.0 Kg´m/88.5 lb in) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Auto Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
9. Install radiator upper fan shroud.
10. Install air cleaner assembly.

6A±33
ENGINE MECHANICAL
Camshaft
Removal
1. Disconnect battery ground cable.
2. Remove crankshaft pulley.

Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.

Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.

Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.

Refer to removal procedure for Cylinder Head
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft
brackets.
014RW027
7. Remove camshaft assembly.
8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque : 10 N´m (1.0 Kg´m/89 lb in)
2. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque : 98 N´m (10.0 Kg´m/72 lb ft)
3. Tighten sub gear setting bolt.
1. Use the 5±8840±2443±0 gear spring lever to turn
sub gear to right direction until it aligns with the M5
bolt hole between camshaft driven gear and sub
gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.

6A±37
ENGINE MECHANICAL
Cylinder Head
Removal
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.

Refer to removal procedure for Crankshaft Pulley in
this manual.
6. Remove timing belt.

Refer to removal procedure for Timing Belt in this
manual.
7. Remove cylinder head cover LH.

Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.

Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.

Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly.
1. Loosen eights bolts for tight cylinder head.
2. Remove cylinder head assembly.
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
Installation
1. Install cylinder head assembly to cylinder block.
1. Put cylinder head gasket on the cylinder block.NOTE: There is discrimination mark ªRº for right bank
and ªLº for left bank on the cylinder head gasket as shown
in the illustration.
Do not reuse cylinder head gasket.
011RW005
2. Align dowel pin hole to dowel pin on the cylinder
block.
3. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
4. Using 9±8511±4209±0 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque :
Temporary : 29 N´m (3.0 Kg´m/21 lb ft)
Final : 64 N´m (6.5 Kg´m/47 lb ft)
014RW029

6A±39
ENGINE MECHANICAL
Valve Stem Oil Controller , Valve Spring and Valve Guide
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.

Drain engine coolant.
3. Remove cylinder head assembly.

Refer to removal procedure for Cylinder Head in
this manual.
4. Remove camshaft.

Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5±8840±2446±0 valve
spring compressor and 5±8840±2547±0 valve spring
compressor adapter then remove upper valve spring
seat and lower seat.
014RW042
7. Remove oil controller using 5±8840±0623±0 oil
controller remover, remove each valve stem oil
controller.
8. Remove valve guide using 5±8840±2549±0 valve
guide replacer.
Installation
1. Install valve guide using 5±8840±2442±0 valve guide
installer.
2. Install oil controller using 5±8840±0624±0 oil
controller installer.
3. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using 5±8840±2446±0 valve spring
compressor and 5±8840±2547±0 valve spring
compressor adapter to install the split collars.
014RW042
4. Install tappet with shim.
5. Install camshaft assembly.

Refer to installation procedure for Camshaft in this
manual.
6. Install cylinder head assembly.

Refer to installation procedure for Cylinder Head in
this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.

6A±40
ENGINE MECHANICAL
Piston, Piston Ring and Connecting Rod
Removal
F06RW011
Legend
(1) Cylinder Head
(2) Crankcase with Oil Pan
(3) Oil Pipe(4) Oil Strainer
(5) Oil Gallery
(6) Piston with Connecting Rod Assembly
1. Remove cylinder head assembly.

Refer to removal procedure for Cylinder Head in
this manual.2. Remove crankcase with Oil Pan.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.

6A±41
ENGINE MECHANICAL
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
4. Remove three fixing bolts, oil pipe with O-ring.
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly, before
removing the bearing cap, remove carbon on the top
of cylinder bore and push piston with connecting rod
out from the top of cylinder bore.
Installation
1. Install piston with connecting rod assembly.

Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.

The bearing cap number must be the same as
connecting rod number.

Apply engine oil to the thread and seating surface of
each nut.

Tighten nuts to the specified torque.
Torque : 54 N´m (5.5 Kg´m/40 lb ft)

After tightening the nuts, make sure that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces
and connecting rod bearing fitting surfaces.
015RW003
Legend
(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark
2. Install oil gallery and tighten the bolts in two steps, in
the order shown in illustration.
Torque :
1st step : 29 N´m (3.0 Kg´m/21 lb ft)
2nd step : 55
±65

051RS009
3. Install oil pipe with O-ring.
Torque : 10 N´m (1.0 Kg´m/89 lb in)
4. Install oil strainer assembly with O-ring.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
5. Install crankcase with Oil Pan.

Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.

Refer to installation procedure for Cylinder Head in
this manual.

6A±42
ENGINE MECHANICAL
Crankshaft and Main Bearings
Removal
F06RW010
Legend
(1) Engine Assembly
(2) Crankshaft Pulley
(3) Timing Belt Cover
(4) Timing Belt
(5) Crankcase with Oil Pan
(6) Oil Pipe
(7) Oil Strainer(8) Oil Pump Assembly
(9) Cylinder Body Side Bolt
(10) Oil Gallery
(11) Flywheel
(12) Rear Oil Seal Retainer
(13) Connecting Rod Cap
(14) Crankshaft Main Bearing Cap
(15) Crankshaft and Main Bearing
1. Remove engine assembly.

Refer to removal procedure for Engine Assembly in
this manual.
2. Remove timing belt.

Refer to removal procedure for Timing Belt in this
manual.3. Remove oil pan and crankcase.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.