engine ISUZU TROOPER 1995 Workshop Manual

6A 1-18 ENGINE (V6 3.2L DOHC AND SOHC)
LH EXHAUST MANIFOLD
I
'
2
6 1
o?~
Removal steps 1.
Air cleaner assembly 2. Exhaust Gas Recirculation pipe
fixing bolts and gasket
3. Exhaust front pipe
4. Heat protector 5. Engine hanger
6. Exhaust manifold
Installation steps To install, follow the removal steps in the reverse order.
E) REMOVAL
Fig. 6A1-19
I••IINSTALLATION
Preparation: Battery ground cable
1. Air cleaner assembly
2. Exhaust Gas Recirculation pipe fixing bolts and
gasket
• Remove from exhaust manifold.
3. Exhaust front pipe
• Remove two stud nuts and two bolts and nuts,
then disconnect
front pipe.
4. Heat protector
• Remove five fixing bolts, then the heat
protector.
5. Engine hanger
• Remove bolt and nut, then engine hanger.
6. Exhaust manifold
• Remove seven nuts and remove exhaust
manifold from the engine.
6. Exhaust manifold
• Tighten nuts to the specified torque with new
one.
1~1 Torque N·m (lb·ft) 57 (42)
5. Engine hanger
4. Heat protector
3. Exhaust front pipe
• Tighten two stud nuts and two bolts and nuts to
the specified torque.
Stud nuts
~~~ Torque N·m (lb·ft) 67 (49)
Bolts and nuts
1~1 Torque N·m (lb·ft) 43 (32)
2. Exhaust Gas Recirculation pipe fixing bolts and
gasket
• Tighten bolts to the specified torque.
~~~ Torque N·m (lb·ft) 28 (21)
1. Air cleaner assembly
..

RH EXHAUST MANIFOLD
4
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-19
Removal steps
1.
Exhaust front pipe 2. Heat protector 3. Engine hanger
4. Exhaust manifold
Installation
steps To install, follow the removal steps in the reverse order.
1••1 REMOVAL
Fig. 6A1-20
I••IINSTALLATION
Preparation: Battery ground cable
1. Exhaust front pipe
• Remove two stud nuts and two bolts and nuts,
then disconnect front pipe.
2. Heat protector
• Remove five fixing bolts, then the heat
protector.
3. Engine hanger
• Remove bolts and nuts that secure the hanger
to the exhaust manifold and cylinder head.
4. Exhaust manifold
• Remove seven nuts, then the exhaust manifold.
4. Exhaust manifold
• Tighten bolts to the specified torque.
I~I_T_or.:....q:....u_e __ N_·m__:_(l_b·_ft.:....) _!._ ___ 5_7_(4_2_) __ _
3.
2.
1.
Engine hanger
Heat protector
Exhaust front pipe
• Tighten two stud nuts and two bolts and nuts to
the specified torque.
Stud nuts
~~~ Torque N·m (lb·ft) 67 (49)
Bolts and nuts
~~~ Torque N·m (lb·ft) 43 (32)

·,'
6A1-20 ENGINE (V6 3.2L DOHC AND SOHC)
TIMING BELT
1 3
2
6 12
~ ..
Fig. 6A1-21
1••1 REMOVAL
Preparation: Battery ground cable
1. Air cleaner assembly
2. Radiator upper fan shroud
• Remove from radiator.
3. Cooling fan assembly
• Remove four nuts, then the cooling fan
assembly.
4. Power steering pump drive belt
5. Air Conditioning compressor drive belt
6. Generator drive belt
7. Fan pulley assembly
8. Crankshaft pulley assembly
~ • Using special tool J-8614-01, hold crankshaft
~ pulley.
•
Remove center bolt, then the pulley.
9. Oil cooler hose
• Remove two cooler hose bracket fixing bolts on
the timing cover.
10. Timing belt cover 11.
Pusher
'IT7 CAUTION:
'if The pusher prevents air from entering the oil
chamber. Its rod must always be facing upward.
12. Timing belt
• To prevent the timing belt from getting out of
position, put the alignment mark on the cam
pulley, the crankshaft pulley and the timing belt
before removing the timing belt.
w CAUTIONS:
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 30mm.
2) Do not allow oil or other chemica[ substances to
come in contact with the belt. They will shorten
the
belt life.
3) Do not attempt to pry or stretch the belt with a
screwdriver or any other tool during installation.
4) Store timing belt in a cool and dark place. Never
expose the
belt to direct sunlight or heat. ~
•

I••IINSTALLATION
12. Timing belt
1£4111) Align groove of crankshaft timing pulley with
mark on oil pump. (Fig. 6A 1-22)
1£4112) Align the marks on the camshaft timing
pulleys with the corresponding dots on the
front plate. (Fig. 6A 1-23)
NOTE:
When timing marks are aligned, no pistons will be
on T.D.C.
,-----------------------------,
Fig. 6A1-22
Groove on timing pulley
Alignment mark on~ ad]
timing belt ·~Alignment mark
DOHC ", ' on front plate Q',
SOHC
Fig. 6A1-23 '"-) ,.· (.)~\,'j
1£4113) Install timing belt. Align the dotted alignment
mark on the timing belt with the mark on the
W crankshaft gear. (Fig. 6A1-24, Fig. 6A1-25)
NOTE:
For correct belt installation, the letters the belt
must be able to be read as viewed from the front
of the vehicle. (Fig. 6A 1-25)
It is recommended for easy installation that
the belt be secured with double clips after it is
installed to each pulley. (Fig. 6A 1-26)
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-21
Alignment mark on timing belt Crankshaft gear alignment mark
L~---
t Cylinder head side
Timing belt
Fig. 6A1-24
Fig. 6A1-25
Fig. 6A1-26
Engine rotation direction
~
Align the alignment mark (white line) on the
timing belt with the alignment mark on the RH
bank camshaft timing pulley (on the left side
as viewed from the front of the vehicle).
Secure
the belt with a double clip. (Fig. 6A 1-
27)

&A 1-22 ENGINE (V& 3.2L DOHC AND SOHC)
Fig. 6A1-27
Alignment mark on ~ timing belt ~
DOHC " ' on front plate
~~
Alignment mark
_","'
SOHC
DOHC
SOHC
/ Alignment mark on timing belt
Fig. 6A1-28
1) Crankshaft timing pulley 2) RH bank timing pulley 3) Water pump pulley 4) Idler pulley 5) LH bank timing pulley 6) Tension pulley
fig. 6A1-29
5) Turn the crankshaft counterclockwise to
remove the belt slack between the crankshaft
timing
pulley and the RH bank camshaft ,.......,,
timing pulley.
6) Install the belt on the water pump pulley.
7) Install the belt on the idler pulley.
8) Align the alignment mark (white line) on the
timing belt with the alignment mark on the
LH
bank camshaft timing pulley.
If
the belt is difficult to install, turn the
camshaft
pulley slightly counterclockwise.
9) Install crankshaft pulley temporarily and
tighten center bolt by hand (do
not use a
wrench). Turn the crankshaft
pulley clockwise
to give some slack between the crankshaft
timing
pulley and the RH bank camshaft
timing
pulley.
1 0) Install the pusher while pushing the tension
pulley to the belt.
11) Pull out the pin from the pusher.
NOTE:
When reusing the pusher, press the pusher to
retract the rod (1.4 mm piano wire). (Fig. 6A 1-30)
Approx. 100 kg
... Direction for installation
Fig. 6A1-30
,.. ..
•

12) Remove double clips from pulleys. Turn the
crankshaft
pulley clockwise by two turns.
Measure the rod protrusion to ensure
it is
within the standard. (Fig. 6A 1-31)
Standard
mm (in) I 4 - 6 (0.16 -0.24)
Adjusting bolt
Pusher
Fig. 6A1-31
13) If out of standard, remove pusher, loosen
adjusting bolt, and readjust. Repeat from step
11 ).
Tighten adjusting bolt to the specified torque
1~1 Torque N·m (lb·ft) I 42 (31)
11. Pusher
• Tighten bolt to the specified torque.
1~1 Torque N·m (lb·ft) I 19 (14)
10. Timing belt cover
• Remove crankshaft pulley that was installed in
step
9.
• Tighten bolts to the specified torque.
~~~ Torque N·m (lb·ft) I 17 (12)
9. Oil cooler hose
• Tighten oil cooler hose bracket bolts to the
specified torque.
~~~ Torque N·m (lb·ft) I 22 (16)
8. Crankshaft pulley
l"iQ\1 • Using special tool J-8614-01, hold the
~ crankshaft pulley.
•
Tighten center bolt to the specified torque.
1~1 Torque N·m (lb·ft) 167 (123)
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-23
7. Fan pulley assembly
• Tighten fixing bolt to the specified torque.
~~~ Torque N·m (lb·ft) 22 (16)
6. Generator drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
5. Air Conditioning drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
4. Power steering pump drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
3. Cooling fan assembly
• Tighten nuts to the specified torque.
~~~ Torque N·m (lb·in) I 8 (69)
2. Radiator upper fan shroud
1. Air cleaner assembly

, r;
6A 1-24 ENGINE (V6 3.2L DOHC AND SOHC)
CRANKSHAFT PULLEY
1 2
7 4
6
3
Removal steps
1. Air
cleaner assembly
2. Radiator upper fan shroud
3. Cooling fan assembly
4. Power steering pump drive belt 5. Air Conditioning compressor
drive belt
6. Generator drive belt 7. Fan pulley assembly
8. Crankshaft pully assembly
Installation
steps To install, follow the removal steps in the reverse order.
Fig. 6A1-32
E) REMOVAL
Preparation: Battery ground cable
1. Air cleaner assembly
2. Radiator upper fan shroud
• Remove from radiator.
3. Cooling fan assembly
• Remove four nuts, then the cooling fan
assembly.
4. Power steering pump drive belt
5. Air Conditioning compressor pump drive belt
6. Generator drive belt
7. Fan pulley assembly
8. Crankshaft pulley assembly
IQil • Using special tool J-8614-01, hold crankshaft
I.:Sil pulley.
•
Remove center bolt, then the pulley.
I••IINSTALLATION
8. Crankshaft pulley
IQil • Using special tool J-8614-01, hold the
I.:Sil crankshaft pulley.
•
Tighten center bolt to the specified torque.
1~1 Torque N·m (lb·ft) 167 (123)
7. Fan pulley assembly
• Tighten fixing bolt to the specified torque.
1~1 Torque N·m (lb·ft) 22 (16)
6. Generator drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
5. Air Conditioning compressor drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
4. Power steering pump drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
3. Cooling fan assembly
• Tighten nuts to the specified torque.
~~~ Torque N·m (lb·in) I
2. Radiator upper fan shroud
1. Air cleaner assembly
8 (69)
•

ENGINE (V6 3.2L DOHC AND SOHC) 6A1-25
CAMSHAFT /ROCKER ARM (SOHC)
1
25
21
1{
24
10 13
17
12 11
14 19
6
27
28
16
Fig. 6A1-33

6A1-26 ENGINE (V& 3.2L DOHC AND SOHC)
1••1 REMOVAL
Preparation: Battery ground cable
1. Air cleaner assembly
2. Radiator upper fan shroud
• Remove from radiator.
3. Cooling fan assembly
• Remove four nuts, then the cooling fan
assembly.
4. Accelerator Pedal cable
• Disconnect from throttle body and cable
bracket.
5. Vacuum booster hose
• Disconnect from common chamber.
6. Connectors
• Disconnect from Manifold Absolute Pressure,
canister Vacuum Switching Valve (VSV),
Exhaust
Gas Recirculation VSV, Intake Air
Temperature and ground cable.
7. High tension cables
• Disconnect from cylinder head cover.
8. Ignition Control Module assembly
• Disconnect three Electronic Ignition con­
nectors.
• Remove three Electronic Ignition bracket fixing
bolts, and remove Electronic
Ignition assembly
with high tension cables.
9. Throttle body
• Remove four fixing bolts.
10. Vacuum hoses
• Disconnect vacuum hoses on canister VSV and
Exhaust Gas Recirculation
VSV from the
throttle body.
11. Positive Crankcase Ventilation hose
• Disconnect from common chamber.
12. Fuel Pressure Control Valve vacuum hose
• Disconnect from common chamber.
13. Evaporative Emission Canister Purge hose
• Disconnect from common chamber.
14. Exhaust Gas Recirculation Valve assembly
• Remove five bolts from common chamber,
exhaust manifold and cylinder head cover.
15. Common chamber
• Remove six bolts, two nuts and three bracket
fixing bolts, then remove the
common
chamber.
16. Fuelhoses
• Disconnect feed and return fuel hoses from fuel
pipes, and remove
two bracket fixing bolts on
the cylinder head cover.
17. Power steering pump drive belt
18. Air Conditioning compressor drive belt
19. Generator drive belt
20. Power steering pump
21. Fan pulley assembly
22. Crankshaft pulley assembly
lf5\l • Using special tool J-8614-01, hold crankshaft
t:::!il pulley.
•
Remove center bolt, then the pulley.
23. Oil cooler hose
• Remove two cooler hose bracket fixing bolts on
the timing belt cover.
24. Timing belt cover
25. Pusher
CAUTION:
The pusher prevents air from entering the oil chamber.
Its rod must always be facing upward.
26. Timing belt
CAUTIONS:
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 30mm.
2) Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the belt life.
3) Do not attempt to pry or stretch the belt with a
screwdriver
or any other tool during installation.
4) Store timing belt in a cool and dark place. Never
expose the belt
to direct sunlight or heat.
27. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
28. Camshaft
• Camshaft pulley fixing bolt and camshaft pulley
•
Front plate fixing bolts and front plate
• Camshaft bracket fixing bolts and camshaft
29. Rocker arm
• Fixing bolts and rocker arm
I••! INSTALLATION
29. Rocker arm
• Tighten bolts to the specified torque.
For the tightening order, see Fig. 6A 1-34.
~~~ Torque N·m (lb·ft) 18 (13)
Fig. 6A1-34
•

28. Camshaft
• Apply sealant (T8-12078 or equivalent) to
contact surfaces of cylinder head with front and
rear camshaft bracket housing as shown in Fig.
6A1-35.
• Tighten camshaft bracket housing fixing bolts
in sequence in illustration (Fig. 6A1-36).
Torque
N·m (lb·in) M6: 8 (69)
N·m (lb·ft) M8: 18 (13)
Sealant application points
Fig. 6A1-35
15 12 7 4 10
13 14 -...;9;..______:a ___ 2--.....-3 ___ s:-..-.:Js 11
M6 Bolts
Fig. 6A1-36
• Tighten front plate fixing bolts to the specified
torque.
~~~ Torque N·m (lb·ft) 17 (12)
• Tighten camshaft pulley fixing bolts to the
specified torque.
~~~ Torque N·m (lb·ft) ___ _____._ ___ _ 63 (46)
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-27
27. Cylinder head cover
• Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and liquid
packing completely. Apply liquid packing (T8-
12078 or equivalent) of bead diameter 2-3 mm
to four places of arched area of camshaft
brackets on front and rear sides. (Fig.6A 1-37)
• Tighten bolts to the specified torque.
~~~ Torque N·m (lb·in)
26. Timing belt
Application points (Front and rear)
Fig. 6A1-37 8
(69)
• Refer to "Timing
belt removal and installation"
in this section.
25. Pusher
• Tighten bolts to the specified torque.
~~~ Torque N·m (lb·ft) I 19 (14)
24. Timing belt cover
• Remove cranksha.ft pulley that was installed in
step 29.
• Tighten bolts to the specified torque.
~~~ · Torque N·m (lb·ft) I 18 (13)
23. Oil cooler hose
• Tighten oil cooler hose bracket bolts to the
specified torque.
1~1 Torque N·m (lb·ft) 18 (13)
22. Crankshaft pulley assembly
lia\1 • Using special tool J-8614-001, hold the
I.::S::il crankshaft pulley.
•
Tighten center bolt to the specified torque.
~~~ Torque N·m (lb·ft) 167 (123)