radiator cap ISUZU TROOPER 1995 User Guide

6A 1-32 ENGINE (V6 3.2L DOHC AND SOHC)
15. Exhaust Gas Recirculation Valve assembly
• Tighten bolts to the specified torque.
Exhaust
Gas Recirculation Valve Side
~~~ Torque N·m (lb·in) J 8 (69)
Exhaust Manifold Side
1~1 Torque N·m (lb·ft) 28 (21)
14. Evaporative Emission Canister Purge hose
13.
Fuel Pressure Control Valve vacuum hose
12. Positive Crankcase
Ventilation hose
10. Throttle body
• Tighten bolts to the specified torque.
Torque
N·m (lb·ft) 19 (14)
11. Vacuum hoses
• Connect vacuum hoses on canister Vacuum
Switching Valve and Exhaust Gas Recirculation
Vacuum Switching Valve
to the throttle body.
9. Ignition Control Module assembly
~ • Tighten bolts to the specified torque and
~ connector.
Torque
N·m (lb·ft)
8. High tension cables
7. Connectors
• Connect each connector.
6. Vacuum booster hose
5. Canister vacuum hose
4. Accelerator Pedal cable
19 (14)
• Accelerator pedal cable adjustment (Fig. 6A 1-
41)
1) Loosen the adjusting nut and screw cap.
2) Pull outer cable while fully closing the
throttle valve.
3) Tighten adjusting nut and screw cap
temporarily.
4) Loosen adjusting nut by three turns and
tighten screw cap.
Then, manually operating the throttle valve,
make sure
that the valve lever returns up to
the stopper screw. If it does not reach the
stopper screw, repeat
from step 1 ).
@:Screw cap
@ : Adjusting nut
Fig. 6A1-41
3. Cooling fan assembly
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·in) I 8 (69)
2. Radiator upper fan shroud
1.
Air cleaner assembly
•

19. Power steering pump drive belt
• Engage and adjust.
• Refer to Section 6B "Drive belt adjustment".
18. Fuel hoses
• Connectthe hoses securely and install the bolts
on the head cover.
17. Common chamber
~~~ • Tighten bolts and nuts to the specified torque.
Bolts
Torque N·m (lb·ft) 24 (17)
Nuts
Torque
N·m (lb·ft) 24 (17)
16. Common chamber duct
~~~ • Tighten bolts and nuts to the specified torque.
Bolts
Torque N·m (lb·ft) 24 (17)
Nuts
Torque
N·m (lb·ft) 24 (17)
• Connect the ground cable.
15. Exhaust Gas Recirculation Valve assembly
~~~ • Tighten bolts to the specified torque.
Exhaust Gas
Recirculation Valve side
Torque
N·m (lb·in) 8 (69)
Exhaust manifold side
Torque
N·m (lb·ft) 28 (21)
14. Evaporative Emission Canister Purge hose
13. Fuel Pressure
Control Valve vacuum hose
12. Positive
Crankcase Ventilation hose
10. Throttle body
~~~ • Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 19 (14)
11. Vacuum hoses
• Connect vacuum hoses on canister Vacuum
Switching
Valve and Exhaust Gas Recirculation
Vacuum Switching Valve to the throttle body.
9. Ignition Control Module assembly
~ • Tighten bolts to the specified torque and
L:::6.l connect connector.
Torque
N·m (lb·ft) 19 (14)
8. High tension cables
7. Connectors
• Connect each connector carefully.
6. Vacuum booster hose
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-37
5. Canister vacuum hose
4. Accelerator Pedal cable
• Accelerator pedal cable adjustment (Fig. 6A 1-
49)
1) Loosen adjusting nut and screw cap.
@:Screw cap
@ : Adjusting nut
Fig. 6A1-49
2) Pull outer cable while closing fully the
throttle body.
3) Tighten adjusting nut and screw cap
temporarily.
4) Loosen adjusting nut by three turns and
tighten
screw cap.
Then,
manually operating the throttle body,
make sure that the
valve lever returns up to
the stopper screw. If it does not reach the
stopper screw, repeat
from step 1 ).
3. Cooling fan assembly
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·in) I 8 (69)
2. Radiator upper fan shroud
1. Air cleaner assembly

ENGINE (V6 3.2L DOHC AND SOHC) 6A1-41
11. Vacuum hoses 2. Radiator upper fan shroud
• Connect vacuum hoses on canister Vacuum 1. Air cleaner assembly
Switching Valve and Exhaust Gas Recirculation
Vacuum Switching Valve to the throttle body.
9.
Ignition Control Module assembly
~ • Tighten bolts to the specified torque and
t::6.l connect connector.
Torque
N·m (lb·ft)
8. High tension cables
7. Connectors
• Connect each connector.
6. Vacuum booster hose
5. Canister vacuum hose
4. Accelerator Pedal cable
19 (14)
• Accelerator pedal cable adjustment (Fig. 6A 1-
51)
1) Loosen adjusting nut and screw cap.
2) Pull outer cable while closing fully the
throttle valve.
3) Tighten adjusting nut and screw cap
temporarily.
4) Loosen adjusting nut by three turns and
tighten
screw cap.
Then,
manually operating the throttle
valve,
make sure that the valve lever
returns up to the stopper screw. If it does
not reach the stopper screw, repeat from
step 1 ).
@:Screw cap
@ : Adjusting nut
Fig. 6A1-51
3. Cooling fan assembly
1«1 • Tighten fixing bolts to the specified torque.
Torque
N·m (lb·in) 8 (69)

16. Common chamber
~~~· Tighten bolts and nuts to the specified torque.
Bolts
Torque N·m (lb·ft) 24 (17)
Nuts
Torque
N·m (lb·ft) 24 (17)
15. Exhaust Gas Recirculation Valve assembly
• Tighten bolts to the specified torque.
Exhaust Gas
Recirculation Valve Side
~~~ Torque N·m (lb·in) I 8 (69)
Exhaust Manifold Side
~~~ Torque N·m (lb·ft) 28 (21)
14. Evaporative Emission Canister Purge hose
13.
Fuel Pressure Control Valve vacuum hose
12. Positive
Crankcase Ventilation hose
11.
Throttle body
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 19 (14)
10. Vacuum hoses
• Connect vacuum hoses on canister Vacuum
Switching Valve and Exhaust Gas Recirculation
Vacuum
Switching Valve to the throttle body.
• Connect Engine Coolant hose and also connect
Idler Air Control Valve and Throttle Position
Sensor connectors.
9. Ignition Control Module assembly
~ • Tighten bolts to the specified torque
~ connect connector. and
Torque
N·m (lb·ft) 19 (14)
8. High tension cables
7. Connectors
• Connect each connector without fail.
6. Vacuum booster hose
5. Canister vacuum hose
ENGINE (V6 3.2L DOHC AND SOHC) 6A 1-45
4. Accelerator Pedal cable
• Accelerator pedal cable adjustment (Fig. 6A 1-
54)
1) Loosen the adjusting nut and screw cap.
2) Pull outer cable while fully closing the
throttle valve.
3) Tighten adjusting nut and screw cap
temporarily.
4) Loosen adjusting nut by three turns and
tighten
screw cap.
Then,
manually operating the throttle
valve, make sure that the valve lever
returns up to the stopper screw. If it does
not reach the stopper screw, repeat
from
step 1 ).
@:Screw cap
@ : Adjusting nut
Fig. 6A1-54
3. Cooling fan assembly
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·in) I 8 (69)
2. Radiator upper fan shroud
1. Air cleaner assembly
NOTE:
• After installation refill the engine coolant. Refer
to Section 68 "Engine cooling".

20. Fuel injector connectors
• Connect to each injector.
19. Fuel hoses
• Connect the hoses securely and install the bolts
on the head cover.
18. Common chamber
• Tighten bolts and nuts to the specified torque.
Bolts
Torque N·m (lb·ft) 24 (17)
Nuts
Torque
N·m (lb·ft) 24 (17)
17. Throttle body
• Connect the engine coolant hose.
16. Common chamber duct
~~~ • Tighten bolts and nuts to the specified torque.
Bolts
Torque N-m (lb·ft) 24 (17)
Nuts
Torque
N·m (lb·ft) 24 (17)
• Connect the ground cable.
15. Exhaust Gas Recirculation Valve assembly
• Tighten bolts to the specified torque.
Exhaust Gas Recirculation
Valve Side
~~~ Torque N·m (lb·in) I 8 (69)
Exhaust Manifold Side
~~~ Torque N·m (lb·ft) 28 (21)
14. Canister vacuum hose
13.
Fuel Pressure Control Valve vacuum hose
12. Positive
Crankcase Ventilation hose
10. Throttle body
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 19 (14)
11. Vacuum hoses
• Connect vacuum hoses on canister Vacuum
Switching Valve and Exhaust Gas Recirculation
Vacuum Switching Valve to the throttle body.
9. Ignition Control Module assembly
~~~· Tighten bolts to the specified torque and
connect connector.
Torque
N-m (lb·ft) 19 (14)
8. High tension cables
7. Connectors
• Connect each connector without fail.
~· 6. Vacuum booster hose
ENGINE (V6 3.2L DOHC AND SOHC) 6A 1-49
5. Canister vacuum hose
4. Accelerator Pedal
cable
• Accelerator pedal cable adjustment (Fig. 6A 1-
57)
1) Loosen adjusting nut and screw cap.
2) Pull outer cable while closing fully the
throttle valve.
3) Tighten adjusting nut and screw cap
temporarily.
4) Loosen adjusting nut by three turns and
tighten
screw cap.
Then,
manually operating the throttle
valve,
make sure that the valve lever
returns up to the stopper screw. If it does
not reach the stopper screw, repeat from
step 1 ).
@:Screw cap
@ : Adjusting nut
Fig. 6A1-57
3. Radiator fan assembly
~~~· Tighten fixing nut to the specified torque.
Torque
N-m (lb·in) I 8 (69)
2. Radiator upper fan shroud
1. Air cleaner assembly
NOTE:
• After installation refill the engine coolant.
Refer to Section 6B "Engine cooling".

68 - 2 ENGINE COOLING
The cooling system is a pressurized Engine Coolant
(EC) forced circulation type which consists of water
pump, thermostat cooling fan, radiator and other
components. The automatic transmission fluid is
cooled by the EC in radiator.
WATER PUMP
Fig. 68-2
The
EC pump is a centrifugal impeller type and is
driven by timing belt. (Fig.68-2)
THERMOSTAT
Jiggle valve
Fig. 68-3
The
thermostat is a wax pellet type with a jiggle
valve and is installed in the thermostat housing.
(Fig.68-3)
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 at
88.2
-117.6 kPa (12.8 - 17.0 psi) pressure. (No oil
cooler
provided for M!f)
Fig. 68-4
ANTI-FREEZE SOLUTION
•
•
Relation between Mixing ratio and Freezing
temperature
of the EC varies with the ratio of
anti-freeze solution in water. Proper mixing
ratio can be determined by referring to the
chart. Supplemental inhibitors or additives
claiming to increase cooling capability that have
not been specifically approved by lsuzu are not
recommended for addition to the cooling
system.
Calculation mixing ratio (Fig. 68-5)
Mixing ratio
Anti-freese
solution (Lit/gal.) =-----------------Anti-freese solution (Lit/gal.) +Water (Lit/gal.)
Note: Anti-freeze solution +Water=
Total cooling system capacity.
Lit (Us
gal)
Total Cooling
M!f 8.5 (2.24) ~-~~--------System Capacity AfT 8.8 (2.32)

Mixing ratio(%) 0 10 20 30 40 50
~
' -10
'
1
' -30

~ -40
In case of 8.5 lit total cooling system capacity
Mixing Anti-freeze
Water: solution: ratio (%) lit. (U.S. gal) lit. (U.S. gal.)
0 0 0
8.5 (2.2) 10 0.9 (0.3) 7.6 (2.0) 15
1.3 (0.4) 7.2 (1.9) 20 1.7 (0.5) 6.8 (1.8)
25 2.1 (0.6) 6.4 (1.7) 30 2.6 (0.7) 5.9 (1.6)
35 3.0 (0.8) 5.5
(1.5) 40 3.4 (0.9) 5.1 (1.3)
45 3.8 (1.0) 4.7 (1.2) 50 4.3 (1.1)
4.2 (1.1)
Fig. 68-5
ENGINE COOLING 68-3
• Mixing ratio
Check
the specific gravity of engine coolant in the
cooling system temperature ranges from oo C to
50° C using a suction type hydrometer, then deter­
mine the densityofthe Engine Coolant by referring
to the table. (Fig. 68-6)
1,100 1'-........ ........ ...... .............. Mixing ratio
~"""--r-... 1'-""' 1,1)90
........ ...... ........ ........ .......... '
1,000
'"" 1,07 o......_ 1'-........ I'-.......... I"-........ .......
I"-........ ..........
................. I"-........
'
1,080
....... I"-........ ~ ........ ......
........ "'" ~"""--r--..... 1,050
r-. ........ ~ .......... ......
---
........ ........ 1,040
r-.... !'--.. 1'-0 '"" ~"""--1'-.... ........ 1,03
1--....... ........ r--~ ........
'
1,020
....... ~ 1'-0 ~"""---.... 1,01
...... ,
'
1,000
10 20 30 40 50 60 70 Coolant temperature ("C)
Fig. 68-6
DIAGNOSIS
ENGINE COOLING TROUBLE
Condition Possible cause Correction
Engine
overheating Low Engine Coolant level Replenish
Thermo unit faulty Replace
Faulty
thermostat Replace
Faulty
Engine Coolant unit Repair or replace
Clogged
radiator Clean or replace
Faulty
radiator cap Replace
Low engine oil level or use of improper Replenish or change oil
engine oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position sensor circuit Repair or replace
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to Faulty thermostat Replace
warm-up Thermo unit faulty Replace

68 - 4 ENGINE COOLING
ON-VEHICLE SERVICE
DRAINING AND REFILLING COOLING
SYSTEM
Before draining the cooling system, inspect the sys­
tem and perform any necessary service to ensure that
it is clean, does not leak and is in proper working
order. The Engine Coolant (EC) level should be be­
tween the "MIN" and "MAX" lines of reserve tank
when the engine is cold. If low, check for leakage and
add
EC up to the "MAX" line. There should not be any
excessive deposit of rust or scales around the radiator
cap
or radiator filler hole, and the EC should also be
free
from oil. Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening
the drain petcock at the bottom of the radiator.
2. Remove the radiator cap.
W WARNING
To avoid the danger of being burned, do not
remove the cap while the engine and radiator
are still hot. Scalding fluid and steam can be
blown out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water,
then drain it. Install the reserve tank and hoses.
WATER PUMP
3
j
2
4. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze but no
more than 70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to "MAX" line when the
engine is cold.
6. Block the drive wheels and firmly apply the park­
ing brake.
Shift an automatic transmission to "P"
(Park) or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and
warm it up at 2,500 -3,000 rpm for about 30
minutes.
8. When the air comes out from the radiator filler
neck and the EC level has gone down, replenish
with the EC. Repeat this procedure until the EC
level does not go down. Then stop the engine and
install the radiator cap. Let the engine cool down.
9. After the engine has cooled, replenish with EC up
to the "MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound
from the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 7
to 10.
Removal steps
1. Timing
belt 2. Idle pulley 3. Water pump assembly
4. Gasket
Installation steps To install, follow the removal steps in the reverse order.
Fig. 6B-7
•

'.,~-' r.
68-8 ENGINE COOLING
2. Radiator hose
• Disconnect inlet hose and outlet hose from the
engine.
3. Fan guide, lower
• Remove clips on both sides and the bottom
lock. (Fig. 68-13)
~ Cooling fan guide; lower
~
Clip
Fig. 68-13
4. Reserve tank hose
• Disconnect the hose from radiator.
5. Bracket
6. Radiator assembly
• Remove upward the radiator assembly with
hose, taking care not to damage the radiator
core
with a fan blade.
• Remove cushion rubbers on both sides at the
bottom.
~ INSPECTION
Radiator Cap
Measure the valve opening pressure of the pressuriz­
ing valve with a radiator filler cap tester. Replace the
cap
if the valve opening pressure is outside the
standard range (Fig. 68-14).
~;!v(~~i~ening pressure 88.3-117.7 (12.8-17.1)
l'i':'il Cap tester: J-24460-01
~ Adapter: J-33984-A
Check the
condition of the negative pressure valve in
the center
of the valve seat side of the cap. If consid­
erable rust
or dirt is found, or if the valve seat cannot
be
moved by hand, clean or replace the cap.
Negative
valve opening
pressure kPa (psi) 1.96-4.91 (0.28-0.71)
Fig. 68-14
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating
may occur. All bent fins must be
straightened. Pay
close attention to the base of the
fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the
Engine
Coolant passages with cold water and mild
detergent. Remove all signs of scales and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196
kPa (28.5 psi) with a cap tester:
• Leakage from the radiator
• Leakage from the coolant pump
• Leakage from the water hoses
• Check the rubber hoses for swelling.
rt:\1 Cap tester: J-24460-01
~ Adapter: J-33984-A
Fig. 68-15
•

E!) INSTALLATION
6. Radiator assembly
• Install cushion rubbers on both sides of radia­
tor bottom.
• Install radiator assembly with hose, taking
care
not to damage the radiator core with a fan
blade.
5. Bracket
• Support the radiator uppertankwith the bracket
and secure the radiator.
4. Reserve tank hose
3. Fan guide, lower
2. Radiator hose
• Connect inlet hose and outlet hose to the
engine.
1. Oil cooler hose (A/T)
• Connect oil cooler hose for automatic trans-
mission.
• Connect battery ground cable.
• Pour engine coolant.
• Pour engine coolant up to filler neck of radia­
tor, and up to MAX mark of reserve tank. (Fig.
68-16)
Reserve tank
Fig. 68-16
ENGINE COOLING 68-9
U7 Important operation (in case of 100% Engine
V Coolant change) procedure for filling with
Engine Coolant
• Fill
with Engine Coolant (EC) to the radiator
filler neck.
• Fill with EC to the "MAX" line on the reservoir.
• Start the engine with the radiator cap removed
and bring
to operating temperature by running
engine at
2,500-3,000 revolution per minute
for 30 minutes.
• By EC temperature gauge reading make sure
that the thermostat is open.
• If air bubbles come up to the radiator filler
neck, replenish with EC repeat until the EC
level does not drop any further. Install the
radiator cap and stop the engine.
• Replenish EC to the "MAX" line on the reser­
voir and leave as it is until the engine gets cool.
• After the engine gets cool, start the engine and
make sure there is no
water running noise
heard
from the heater core while the engine
runs
at 3000 revolution per minute.
• Should water running noise be heard, repeat
the same procedure from the beginning.