radiator ISUZU TROOPER 1998 Service Manual PDF

4JG2-NA/4JG2-TURBO ENGINE 6A2Ð 35
INSTALLATION
6. Oil Cooler
·Tighten oil cooler fixing bolt to the specified
torque and connect water hose.
5. Exh. Adapter (4JG2-T Only)
·Install exhaust duct with gasket and tighten fixing
bolts to the specified torque.
26 (2.7/20)N·m(Kg·m/lb·ft)
4. Heat Protector (4JG2-T Only)
3. Front Exh. Pipe
·Install front exhaust pipe and tighten fixing bolts
to the specified torque.
2. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler installation steps in section.
·Pour coolant into radiator.
·Install battery ground cable.
·Start engine and check for oil and water leakage
carefully.
1. Air Cleaner Cover & Air Duct
67 (6.8/49)N·m(Kg·m/lb·ft)
Exh Dust Side
43 (4.4/32)N·m(Kg·m/lb·ft)
Intermediate pipe side 29 (3.0/22)N·m(Kg·m/lb·ft)

6A2 Ð 48 4JG2-NA/4JG2-TURBO ENGINE
ENGINE ASSEMBLY
REMOVAL
Preparation
·Space stands and removal front tires.
·Removal battery. (two batteries for cold area)
·Drain coolant.
·Disconnect window washer hose and remove engine
hood.
1. Radiator Hose
·Disconnect upper and lower hoses from engine
side.
2. Fan Shroud
·Disengage clips and remove upper and lower fan
shrouds.

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 49
3. Cooling Fan Assembly
·Remove cooling fan asm fixing nuts, cooling fan
asm, fan pulley and center.
4. Radiator Assembly
·Remove bracket and radiator asm.
5. Air Cleaner Cover & Air Duct
6. Intercooler Assembly (4JG2 -T only)
·(Refer to Intercooler removal steps in this section)
7. P/S Pump Drive Belts
·Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belts.
8. P/S Pump Assembly
·Remove two fixing bolts (front side), a fixing nut
(rear side) and support P/S pump asm with oil
hoses by tying to body side.
9. Engine Ground Cable
·Disconnect ground cable from A/C compressor
bracket.
10. AC Generator Harness
·Disconnect B terminal and harness connector
from AC generator.
11. A/C Compressor Assembly
·Remove A/C compressor fixing bolt (rear under
side of compressor) by using a long extension bar
at under side of wheel arch.
·Disconnect magnetic clutch harness connector.
·Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor asm with
pipe lines on battery carrier.
12. Vacuum Hose: Vacuum Pump
·Disconnect vacuum hose from vacuum pump.
13. Starter Harness
·Disconnect B terminal and put cable harness close
to chassis side.
·Disconnect S terminal connector.
14. Engine Harness.
·Disconnect engine harness close to engine side.
15. Accelerater Cable
·Loosen locking nut at bracket and disconnect
accelerater cable from injection pump control
lever.
16. Fuel Hoses
·Disconnect fuel hoses from injection pump side
and take care not to spill fuel and enter dust.
17. Engine Ground Cable
·Disconnect ground cable from left rear side of
timing gear case.

6A2 Ð 52 4JG2-NA/4JG2-TURBO ENGINE
6. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler installation steps in this
section.
5. Air Cleaner Cover & Duct
4. Radiator Assembly
·Install cushion rubber in under left and right part
of radiator and position radiator.
·Fix radiator by bracket.
3. Cooling Fan Assembly
·Install cooling fan asm and tighten fixing bolts to
the specified torque.
2. Fan Shroud
1. Radiator Hose
·Connect upper and lower hose to engine side.
·Pour coolant in to radiator.
·Install battery.
·Connect window washer hose.
10. A.C. Generator Harness
9. Engine Ground Cable
·Attached ground cable to A/C compressor bracket.
8. P/S Pump Assembly
·Install P/S pump asm in engine and tighten
temporarily fixing nut.
7. P/S Pump Drive Belt
·Install drive belts adjust belt tension by adjusting
bolt and tighten locking bolt to the specified
torque.
·Refer to ÒDrive Belt AdjustmentÓ in section 6B.
8 (0.8/69)N·m(Kg·m/lb·in)
40 (4.1/30)N·m(Kg·m/lb·ft)

ENGINE COOLING 6B Ð 1
SECTION 6B
ENGINE COOLING
CONTENTS
PAGE
General Description ..................................................................................................................... 6B- 1
On-Vehicle Service ....................................................................................................................... 6B- 5
Water Pump ............................................................................................................................. 6B- 5
Thermostat ............................................................................................................................... 6B- 7
Radiator .................................................................................................................................... 6B- 9
Drive Belt Adjustment ............................................................................................................ 6B-15
GENERAL DESCRIPTION

ENGINE COOLING 6B Ð 3
The cooling system is a pressurized coolant forced
circulation type which consists of water pump, thermostat
cooling fan, radiator and other components. The
circulating coolant cools the lubricating oil in the oil filter
and turbocharger.
WATER PUMP
The coolant pump is a centrifugal impeller type and is
driven by V type drive belt.
THERMOSTAT
The thermostat is a wax pellet type with a jiggle valve and
is installed in the thermostat housing.
RADIATOR
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of coolant, the radiator is fitted
with a cap in which the valve is operated under the
pressure.

ENGINE COOLING 6B Ð 7
THERMOSTAT
REMOVAL
Preparation
·Disconnect battery ground cable.
·Drain coolant from the radiator and engine.
1. Water Hose; Turbocharger (4JG2-T Only)
2. Outlet Pipe
·Remove mounting bolt and remove outlet pipe
together with radiator hose.
3. Gasket
4. Thermostat
INSPECTION
Submerge the thermostat assembly in the water.
Place wooden blocks on the bottom of the water
container.
Not to directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
·Make sure that primary valve begins to open at the
specified temperature.
82 (180 )
°C (°F) Valve Opening Temperature

ENGINE COOLING 6B Ð 9
RADIATOR
REMOVAL
Preparation
·Disconnect battery ground cable.
·Loosen drain plug to drain coolant.
1. Radiator Hose
·Disconnect lower hose and upper hose from the
engine.
2. Fan Guide Lower
·Remove clips on both sides and the bottom lock.
3. Reservoir Tank Hose
·Disconnect the hose from radiator.
4. Bracket
5. Radiator Assembly
·Remove upward the radiator assembly with hose,
taking care not to damage the radiator core by fan
blade.
·Remove cushion rubbers on both sides of the
bottom.
INSPECTION
Radiator Cap
·Measure the valve opening pressure with the radiator
cap tester. Replace the radiator cap if it exceeds the
standard.
Check the condition of negative pressure valve in the
center of valve seat side of the cap. If the valve seat
does not move smoothly due to rust or dust, clean or
replace the radiator cap.
Valve opening pressure
93.3 – 122.7 (0.95 – 1.25/13.5 – 17.8)kPa(Kg/cm2 / psi)

6B Ð 10 ENGINE COOLING
Radiator Core
·Deformed radiator fins could reduce radiation effects,
resulting in overheat. Straighten the fins. In such a
case, take care not to damage the fin roots.
·Remove dust and other foreign materials.
Flushing the Radiator
·Wash the inside of radiator and the coolant passage
with water and neutral detergent. Remove all scales
and rust.
Checking for Coolant Leakage
·Check the cooling system for leakage with the radiator
cap tester by applying 196.0kPa (28.4 psi) air pressure
from filler neck to inside the radiator.
INSTALLATION
5. Radiator Assembly
·Install cushion rubbers on both sides of radiator
bottom.
·Install radiator assembly with hose, taking care not
to damage the radiator core by a fan blade.
4. Bracket
·Support the radiator upper tank with the bracket
and fix the radiator.
3. Reserve Tank Hose
2. Fan Guide, Lower
1. Radiator Hose
·Connect inlet hose and outlet hose to the engine.
·Connect battery ground cable.
·Pour coolant
·Pour coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
·Start engine to warm up, and check for coolant
level. Replenish coolant if it does not reach the
radiator filler neck, and tighten the cap completely.

6C Ð 14 FUEL SYSTEM
INJECTION PUMP ASSEMBLY
Removal Steps
1. Air cleaner cover & air duct
2. Intercooler assembly
3. Radiator assembly
4. Cooling fan assembly
5. P/S pump drive belt
6. AC generator drive belt7. Timing gear
8. Fuel filter assembly
9. Injection pump harness
10. Fuel hose and CSD hose
11. Injection pump Control cable
12. Injection pipe
13. Injection pump assembly
Installation Steps
To install, follow the removal steps in
the reverse order.