ISUZU TROOPER 1995 Workshop Manual

ENGINE (V6 3.2L DOHC AND SOHC} SA 1 33
TIMING CHAIN (DOHC}
1 4
2
8
13
17
16 11 18
17
27~
24
22
~~
31
30
21 ~· Fig. 6A1-42

6A1-34 ENGINE (V6 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. Canister vacuum hose
• Disconnect from vacuum pipe.
6. Vacuum booster hose
• Disconnect from common chamber.
7. Connectors
• Disconnect from Manifold Absolute Pressure,
canister Vacuum Switching Valve (VSV),
Exhaust Gas Recirculation VSV, Intake Air
Temperature and ground cable.
8. High tension cables
• Disconnect from cylinder head cover.
9. 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.
10. Throttle body
• Remove four fixing bolts.
11. Vacuum hoses
• Disconnect vacuum hoses on canister VSV and
Exhaust Gas Recirculation
VSV from the
throttle body.
12. Positive Crankcase Ventilation hose
• Disconnect from common chamber.
13. Fuel Pressure Control Valve vacuum hose
• Disconnect from common chamber.
14. Evaporative Emission Canister Purge hose
• Disconnect from common chamber.
15. Exhaust Gas Recirculation Valve assembly
• Remove five bolts from common chamber,
exhaust manifold and cylinder head cover.
16. Common chamber duct
• Remove four bolts, four nuts and three bracket
fixing
bolts, then remove the common
chamber duct.
• Disconnect ground cable from rear side of
common chamber.
17. Common chamber
• Remove six bolts, two nuts and three bracket
fixing
bolts, then remove the common
chamber.
18. Fuel hoses
• Disconnect feed and return fuel hoses from fuel
pipes, and remove two bracket fixing bolts on
the cylinder head cover.
19. Power steering pump drive belt
20.
Air Conditioning compressor drive belt
21. Generator drive belt
22. Power steering pump
23.
Fan pulley assembly
24. Crankshaft pulley assembly
liQil • Using special tool J-8614-01, hold crankshaft
~ pulley.
• Remove center bolt, then the pulley.
25. Oil cooler hose
• Remove two cooler hose bracket fixing bolts on
the
timing belt cover.
26. Timing belt cover
27. Pusher
\fl CAUTION:
'V The pusher prevents air from entering the oil
chamber. Its rod must always be facing upward.
28. Timing belt
\fl CAUTIONS:
'V 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.
29. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
30. Camshaft timing pulley
31. Front plate
32. Camshaft brackets
33. Chain tensioner fixing
bolts
34. Camshaft
• Remove the camshaft with chain and chain
tensioner.
35. Oil seal and camshaft end plug
II

1••1 INSTALLATION
34. Camshaft
u
• Install camshaft with chain and chain tensioner.
NOTE:
Install a retainer on the tensioner as shown in Fig.
6A 1-43 to prevent plunger from moving and
remove
it after securely installing camshaft.
2)
Fig. 6A1-43
Apply engine oil sufficiently to the following
points.
1 Camshaft
journal
2 Camshaft sprocket
Install camshaft on cylinder head.
1
Align sprocket timing mark to chain timing
mark (Fig. 6A1-44).
2 Take care
not to install wrong chain
tensioners,
as left and right tensioners are
different from each other.
Each tensioner
is marked with either R
(right)
or L (left) (Fig. 6A1-45).
Timing mark
Fig. 6A1-44
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-35
Left side
Moving side
Position mark
Fig. 6A1-45
33. Chain tensioner fixing bolts
• Tighten the bolts.
1~1 Torque N·m (lb·ft)
32. Camshaft brackets
Right side
19 (14)
m 1) Remove any oil from the contact surfaces on
l..QI the intake and exhaust sides of #1 and #6
camshaft bearing caps on the cylinder head.
~~~2) Apply sealant (TB-12078 or equivalent) to
contact surfaces of cylinder head with # 1 and
#6 camshaft bracket as shown in Fig. 6A 1-46.
Sealant application points
Fig. 6A1-46
U7 CAUTION:
VI Do not apply an excessive amount of sealant to
the contact surface. Applying too much sealant
will result in the coating overflowing the contact
surface. This
could cause the serious damage of
the engine.
3) Mount the camshaft bracket on the cylinder
head.
4) Tighten camshaft bracket bolts in sequence,
as shown in the illustration (Fig. 6A1-47).

6A1-36 ENGINE (V6 3.2L DOHC AND SOHC)
Q : Intake side 0 : Exhaust side
Fig. 6A1-47
\f7 • The "E" mark is applied to the camshaft bracket
VI exhaust side and, on the other hand, the "I"
mark is applied to the intake side. Install the
camshaft bracket in the
numerical order (1, 2, 3,
4, 6) from the camshaft end without the
sprocket.
• The camshaft bracket arrow marks must be
pointing towards the camshaft end
without the
sprocket.
~~~ Torque N·m (lb·in) 10 (87)
35. Oil seal and camshaft end plug
D • Apply engine oil to the camshaft oil seal lip and
L::J install new camshaft oil seal
1®.1 Camshaft oil seal Installer: J-39203
31. Front plate
~ • Tighten front plate fixing bolts to the specified
~ torque.
~ Torque N·m (lb·ft) 19 (14)
30. Camshaft timing pulley
• Tighten camshaft pulley fixing bolts to the
specified torque
~ Torque N·m (lb·ft) 63 (46)
29. Cylinder head cover
m • Clean the sealing surface of cylinder head and
t..al cylinder head cover to remove oil and sealing
Jail material completely. Apply sealant (T8-12078
I..:!LI or equivalent) of bead diameter 2-3 mm to four
places of arched area of camshaft brackets on
front and rear sides. (Fig. 6A1-48)
~~~ • Tighten bolts to the specified torque.
Torque
N·m (lb·in) I 8 (69)
Application points (Front and rear)
28. Timing belt
Fig. 6A1-48
• Refer to "Timing belt removal and installation"
in this section.
27. Pusher
• Tighten bolt to the specified torque.
~~~ Torque N·m (lb·ft) 19 (14)
26. Timing belt cover
• Remove crankshaft pulley that was installed in
step
30.
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 18 (13)
25. Oil cooler hose
~ • Tighten oil cooler hose bracket bolts to the
~ specified torque.
Torque
N·m (lb·ft) 18 (13)
24. Crankshaft pulley assembly
1?.:\1 • Using special tool J-8614-01, hold the
~ crankshaft pulley.
~~~ • Tighten center bolt to the specified torque.
Torque
N·m (lb·ft) 167 (123)
23. Fan pulley assembly
~~~· Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) J 22 (16)
22. Power steering pump
~ • Tighten pump fixing bolts to the specified
~ torque.
Torque
N·m (lb·ft) 46 (34)
21. Generator drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
20. Air Conditioning compressor drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".

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

&A 1-38 ENGINE (V6 3.2L DOHC AND SOHC)
l;J .:". VALVE STEM OIL CONTROLLER AND VALVE SPRING
6
23 •
10 18(SOHC)
3
~18
. 18(DOHC)
16(DOHC)
11
17(DOHC) 15
-ri>J
17(SOHC) 24
~ 32(SOHC)
30(DOHC)
t·
20
33
/If)
21 30(SOHC) 35 34
Fig. 6A1-50
•

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. Accelerator Padal cable
• Disconnect from throttle body and cable
bracket.
5. Canister vacuum hose
• Disconnect from vacuum pipe.
6. Vacuum booster hose
• Disconnect from common chamber.
7. Connectors
• Disconnect from Manifold Absolute Pressure,
canister Vacuum
Switching Valve (VSV),
Exhaust Gas Recirculation VSV, Intake Air
Temperature and ground cable.
8. High tension cables
• Disconnect from cylinder head cover.
9.
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.
10.
Throttle body
• Remove four fixing bolts.
11. Vacuum hoses
• Disconnect vacuum hoses on canister VSV and
Exhaust Gas Recirculation
VSV from the
throttle body.
12.
Positive Crankcase Ventilation hose
• Disconnect from common chamber.
13.
Fuel Pressure Control Valve vacuum hose
• Disconnect from common chamber.
14.
Evaporative Emission Canister Purge hose
• Disconnect from common chamber.
15.
Exhaust Gas Recirculation Valve assembly
• Remove five bolts from common chamber,
exhaust
manifold and cylinder head cover.
16.
Common chamber duct (DOHC)
• Remove four bolts, four nuts and three bracket
fixing
bolts, then remove the common
chamber duct.
• Disconnect ground cable from rear side of
common chamber.
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-39
17. Common chamber
• Remove six bolts, two nuts and three bracket
fixing
bolts, then remove the common
chamber.
18.
Fuelhoses
• Disconnect feed and return fuel hoses from fuel
pipes, and remove two bracket fixing bolts on
the
cylinder head cover.
19.
Power steering pump drive belt
20. Air Conditioning compressor drive belt
21. Generator drive belt
22. Power steering pump
23. Fan pulley assembly
24. Crankshaft pulley assembly
~ • Using special tool J-8614-01, hold crankshaft
~ pulley.
•
Remove center bolt, then the pulley.
25. Oil cooler hose
• Remove two cooler hose bracket fixing bolts on
the timing
belt cover.
26.
Timing belt cover
27. Pusher
\fl CAUTION:
'if The pusher prevents air from entering the oil
chamber. Its rod must always be facing upward.
28.
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.
29.
Cylinder head cover
30. Camshaft
• Camshaft pulley fixing bolt and camshaft pulley
•
Front plate fixing bolts and front plate
• Chain
tensioner fixing bolts (DOHC) and
camshaft bracket fixing
bolts
•
Camshaft, oil seal and camshaft end plug
31. Swing arm (DOHC)
32. Rocker
arm (SOHC)
•
Fixing bolt and rocker arm
33.
Spark plugs
• Keep valve in home position by feeding the
compressed air to the
cylinder from spark plug
hole.

6A 1-40 ENGINE (V6 3.2L DOHC AND SOHC)
34. Valve springs
35.
• Refer to section 6A "Valve springs oil
controller, valve, valve guide (and HLA for
DOHC)" removal.
Valve stem oil controllers
~·
Using special tool, remove each valve stem oil
controller.
Remover: J-37281
1••1 INSTALLATION
35. Valve stem oil controllers
• Refer to Section 6A "Valve springs, oil
controller, valve, valve guide (and HLA for
DOHC)" installation.
34. Valve springs
li5\l • Using special tool, install each valve spring.
~ Spring compressor: J-39251
33. Spark plugs
~~~· Tighten each spark plug to the specified torque.
Torque
N·m (lb·ft) I 18 (13)
32. Rocker arm (SOHC)
~~~ • Tighten bolt to the specified torque.
Torque
N·m (lb·ft) I 18 (13)
31. Swing arm (DOHC)
30. Camshaft
• Refer to Section 6A "Camshaft installation".
29. Cylinder head cover
~~~ • Tighten bolts to the specified torque.
Torque
N-m (lb·in) I 8 (69)
28. Timing belt
• Refer to "Timing belt removal and installation"
in this section.
27. Pusher
• Tighten bolt to the specified torque.
~~~ Torque N·m (lb·ft) 19 (14)
26. Timing belt cover
• Remove crankshaft pulley that was installed in
step
30.
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb-ft) I 18 (13)
25. Oil cooler hose
~ • Tighten oil cooler hose bracket bolts to the
~ specified torque.
Torque
N-m (lb·ft) I 18 (13)
24. Crankshaft pulley assembly
f'Qil • Using special tool J-8614-01, hold the
~ crankshaft pulley.
~~~· Tighten center bolt to the specified torque.
Torque
N·m (lb·ft) I 167 (123)
23. Fan pulley assembly
~~~ • Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) I 22 (16)
22. Power steering pump
~ • Tighten pump fixing bolts to the specified
~ torque.
Torque
N·m (lb·ft) 56 (41)
21. Generator drive belt
• Engage and adjust.
• Refer to Section 6B "Drive belt adjustment".
20. Air Conditioning compressor drive belt
• Engage and adjust.
• Refer to Section 6B "Drive belt adjustment".
19. Power steering pump drive belt
• Engage and adjust.
• Refer to Section 6B "Drive belt adjustment".
18. Fuel hoses
• Connect surely the hoses 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 (DOHC)
~~~ • 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) 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)
..

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)

6A 1-42 ENGINE (V6 3.2L DOHC AND SOHC)
CYLINDER HEAD (SOHC)
16 2 16
33
1
~30
27 20
19
37
6
24
15
33
Fig. 6A1-52
..