ISUZU TROOPER 1995 Workshop Manual

EJ REMOVAL
Preparation: • Remove engine hood.
• Drain radiator Engine Coolant.
• Disconnect battery ground cable.
1. Air cleaner assembly
2. Radiator upper fan shroud
• Remove from radiator.
3. Radiator fan assembly
• Remove four nuts, then the radiator fan
assembly.
4. Accelerator Pedal cable
• Disconnect from throttle body and cable
bracket.
5. Canister vacuum hose
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 assembly
16. Common chamber
• Remove six bolts, two nuts and four bracket
fixing bolts, then remove the
common
chamber.
17. Throttle body
• Disconnect Engine Coolant hose from throttle
body.
• Disconnect Idler Air Control Valve and Throttle
Position Sensor connectors.
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-43
18. Fuelhoses
• Disconnect feed and return fuel hoses from fuel
pipes, and remove two bracket fixing bolts on
the cylinder head cover.
19. Fuel injector connectors
• Disconnect connectors from injectors.
• Disconnect thermo sensor connector.
20. Intake manifold
• Remove two fixing bolts and four nuts.
21. Engine Coolant manifold
• Disconnect heater hose.
• Remove four fixing bolts.
22. Power steering pump drive belt
23. Air Conditioning compressor drive belt
24. Generator drive belt
25. Power steering pump
26.
Fan pulley assembly
27. Crankshaft pulley assembly
~ • Using special tool J-8614-01, hold crankshaft
~ pulley.
•
Remove center bolt, then the pulley.
28. Oil cooler hose
• Remove two cooler hose bracket fixing bolts on
the timing
belt cover.
29. Timing belt cover
30. Pusher
\fl CAUTION:
VI The pusher prevents air from entering the oil
chamber. Its rod must always be facing upward.
31. Timing belt
\fl CAUTIONS:
VI 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.
32. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
33. Power steering pump bracket
• Disconnect ground cable from bracket.
• Remove five fixing bolts, then the bracket.
34. Exhaust front pipe
35.
Level gage guide tube fixing bolt
• Remove from cylinder head.
36. Cylinder head

'.:.:.
6A1-44 ENGINE (V6 3.2L DOHC AND SOHC)
1••1 INSTALLATION
36. Cylinder head
l"i:a\1 • Using special tools, tighten fixing bolts to the
~ specified torque, in sequence shown in
Fig.
6A 1-53.
Extension wrench: J-39252
Extension wrench: J-24239-01
NOTE:
• Do not reuse cylinder head gasket and M11
fixing bolts.
• Do not apply the oil to the bolt.
M8x1.25
1~1 Torque N·m (lb·ft)
M11x1.5
21 (15)
~~~ Torque N·m (lb·ft) 64 (47)
[ill ® ® @ , , , I I I
~
I
I I
I I
I I I
I I
I I I
I I
I

0
' , , ' ' , ' , ' ® '-~ CD @
M8 Bolt QM11Bolt
Fig. 6A1-53
35. Level gage guide tube fixing bolt
34. Exhaust front pipe
' '
, ,
(j)
I
I
I
@
~~~ • Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) I 67 (48)
33. Power steering pump bracket
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 46 (34)
32. Cylinder head cover
• Refer to "Cylinder head cover removal and
installation" in this section.
31. Timing belt
• Refer to "Timing belt removal and installation"
in this section.
30. Pusher
• Tighten bolt to the specified torque.
1~1 Torque N·m (lb·ft) I 19 (14)
29. Timing belt cover
• Remove crankshaft pulley that was installed in
step
33.
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 18 (13)
28. Oil cooler hose
~ • Tighten oil cooler hose bracket bolts to the
~ specified torque.
Torque
N·m(lb·ft) I 18(13)
27. Crankshaft pulley assembly
l"i:a\1 • 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)
26. Fan pulley assembly
~~~ • Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) I 22 (16)
25. Power steering pump
~ • Tighten pump fixing bolts to the specified
~ torque.
Torque
N-m (lb·ft) 46 (34)
24. Generator drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
23. Air Conditioning compressor drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
22. Power steering pump drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
21. Engine Coolant manifold
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) J 22 (16)
• Connect heater hose.
20. Intake manifold
~ • Tighten fixing bolts and nuts to the specified
~ torque.
Bolts
Torque N-m (lb·ft) 24 (17)
Nuts
Torque
N-m (lb·ft) 24 (17)
19. Fuel injector connectors
• Connect to each injector.
18. Fuelhoses
• Connect the hoses securely and install the bolts
on the head cover.
17. Throttle body
..

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".

..
6A 1-46 ENGINE (V6 3.2L DOHC AND SOHC) ;;:..
CYLINDER HEAD (DOHC)
2
27 7
~
3 9
16
12
15
18 17 21
31
~
32
Fig. 6A1-55
..

1••1 REMOVAL
Preparation: • Remove engine hood.
• Drain radiator Engine Coolant.
•
Disconnect battery ground cable.
1.
Air cleaner assembly
2. Radiator upper fan shroud
• Remove from radiator.
3. Radiator fan assembly
• Remove four nuts, then the radiator 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.
Canister vacuum 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.
• Disconnect ground cable from rear side of
common chamber.
ENGINE (V6 3.2L DOHC AND SOHC) 6A1 47
17. Throttle body
• Disconnect Engine Coolant hose from throttle
body.
• Disconnect Idle Air Control Valve and Throttle
Position Sensor connectors.
18.
Common chamber
• Remove six bolts and two nuts.
• Remove fixing bolts on common chamber
bracket, then the
common chamber.
19.
Fuelhoses
• Disconnect feed and return fuel hoses from fuel
pipes, and remove
two bracket fixing bolts on
the cylinder head cover.
20. Fuel injector connectors
• Disconnect connectors from injectors.
• Disconnect thermo sensor connector.
21.
Intake manifold
• Remove two fixing bolts and four nuts.
22. Engine
Coolant manifold
• Disconnect heater hose.
• Remove four fixing bolts.
23.
Power steering pump drive belt
24. Air Conditioning compressor drive belt
25. Generator drive belt
26. Power steering pump
27. Fan pulley assembly
28. Crankshaft pulley assembly
I®J • Using special tool J-8614-01, hold crankshaft
pulley.
•
Remove center bolt, then the pulley.
29. Oil cooler hose
• Remove two cooler hose bracket fixing bolts on
the timing belt cover.
30. Timing belt cover
31. Pusher
CAUTION:
The pusher prevents air from entering the oil
chamber. Its rod must always be facing upward.
32.
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 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.

~:· T·, ·.}:
6A1-48 ENGINE (V6 3.2L DOHC AND SOHC)
33. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
34. Power steering pump bracket
• Disconnect ground cable from bracket.
35.
• Remove five fixing bolts, then the bracket.
Exhaust front pipe
36.
37. Level gage fixing bolt
• Remove from cylinder head.
Cylinder head
1••1 INSTALLATION
37. Cylinder head
li0\1 • Using special tools, tighten fixing bolts to the
~ specified torque, in sequence shown in Fig.
6A1-56.
~ Extension wrench: J-39252
t:6.l Extension wrench: J-24239-01
NOTE:
• Do not reuse cylinder head gasket and M11
fixing bolts.
•
Do not apply the oil to the bolt.
M8x1.25
Torque
N·m (lb·ft) 21 (15)
M11x1.5
Torque
N·m (lb·ft) 64 (47)
OJ] ® ® ® , ' ' ,
, I , ,
[IQJ ' I I
I I
I I I
I I
I I I
I I
,
[I] ' , , ' @ ' ,
CD ' , , __
@
[[ M8 Bolt (J M11 Bolt
Fig.
6A1-56
36. Level gage guide tube fixing bolt
35. Exhaust front pipe
'
,
(])
I
I
I
,
@
~~~ • Tighten fixing bolt to the specified torque.
Torque
N·m (lb·ft) I 67 (49)
34. Power steering pump bracket
~~~ • Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 46 (34)
33.
32.
31.
Cylinder head cover
• Refer to "Cylinder head cover removal and
installation" in this section
Timing belt
• Refer to "Timing belt removal and installation"
in this section.
Pusher
• Tighten bolt to the specified torque.
I~I __ T_o_r~qu_e __ N_·_m~(lb_·ft_)~ ______ 1_9_(1_4_) ____ _
30. Timing belt cover
• Remove crankshaft pulley that was installed in
step 34.
~~~· Tighten bolts to the specified torque.
Torque
N·m (lb·ft) I 18 (13)
29. Oil cooler hose
~ • Tighten oil cooler hose bracket bolts to the
t:6.l specified torque.
Torque
N·m (lb·ft) I 18 (13)
28. Crankshaft pulley assembly
li0\1 • Using special tool J-8614-011 hold the
~ crankshaft pulley.
~~~ • Tighten center bolt to the specified torque.
Torque
N·m (lb·ft) I 167 (123)
27. Fan pulley assembly
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 22 (16)
26. Power steering pump
~ • Tighten pump fixing bolts to the specified
t:6.l torque.
Torque
N·m (lb·ft) I 46 (34)
25. Generator drive belt
• Refer to Section 68 "Drive belt adjustment".
24.
Air Conditioning compressor drive belt
• Refer to Section 68 "Drive belt adjustment".
23. Power steering pump drive belt
• Refer to Section 68 "Drive belt adjustment".
22. Engine Coolant manifold
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 22 (16)
• Connect heater hose.
21.
Intake manifold
~ • Tighten fixing bolts and nuts to the specified
t:6.l torque.
Bolts
Torque N·m (lb·ft) 24 (17)
Nuts
Torque
N·m (lb·ft) 24 (17)
..

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".

6A1 50 ENGINE (V6 3.2L DOHC AND SOHC)
OIL PAN
1
6
Removal steps 1. Oil level dipstick
2. Stone guard
3. Radiator under fan shroud
4. Suspension crossmembers
5.
Flywheel dust cover
6. Pitman arm and
idler arm
7. Axle housing assembly 8. Oil pan fixing bolts and nuts
9. Oil pan
Installation steps
To install, follow the removal steps in the reverse order.
Fig. 6A1-58
1••1 REMOVAL
Preparation: • Disconnect battery ground cable.
•
Drain engine oil.
•
Lift vehicle by supporting the frame.
• Remove front wheels.
1. Oil level dipstick
• Remove a dip stick from level gage tube.
2. Stone guard
3. Radiator under fan shroud
4.
5.
6.
Suspension crossmembers
• Remove fixing bolts, 2 pes each per side.
Flywheel dust cover
Pitman arm and
idler arm
~·
Using the special tool, remove pitman arm
from the steering unit.
Remover: J-291
07
• Remove four fixing bolts four idler arm.
7. Axle housing assembly
• Remove two bolts and nuts from housing
isolators on both sides. Atthis time, supportthe
axle with a garage jack.
8. Oil pan fixing bolts and nuts
9. Oil pan (Fig. 6A1-59)
fiOil • Using sealer cutter, remove oil pan.
~ Sealer cutter: J-37228
NOTE:
Do not deform or damage the flange of oil pan.
Replace the oil pan if deformed or damaged.
•

.., ¢'
-
Fig. 6A1-59
1••1 INSTALLATION
9. Oil pan (Fig. 6A1-60)
m • Remove residual sealant, lubricant and
~ moisture from mounting surface, then dry
throughly.
ISPI• Apply a properly wide bead of sealant (TB-
1207C or equivalent) to mounting surface of oil
pan. Sealant bead must be continuous.
• Oil pan must be installed within 5 minutes after
sealant is applied.
4.3mm (0.17in.) width bead of sealant
Portions between bolt holes
Fig. 6A1-60
8. Oil pan fixing bolts and nuts
Bolt hole portions
~ • Tighten oil pan fixing bolts and nuts to the
~ specified torque.
Torque
N·m (lb·in)
10 (87)
7. Axle housing assembly
~~~· Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) 82 (61)
• Tighten fixing bolts and nuts to the specified
torque.
Torque
N·m (lb·ft) 152 (112)
ENGINE (V6 3.2L DOHC AND SOHC) 6A 1-51
6. Pitman arm and idler arm
~·
Tighten idler arm fixing bolt to the specified
torque.
Torque
N·m (lb·ft) 44 (33)
• Engage teeth of pitman arm and steering unit,
and tighten
bolt to the specified torque.
Torque
N·m (lb·ft) 216 (159)
5. Flywheel dust cover
4. Suspension cross member
~~~ • Tighten fixing bolts to the specified torque.
Torque
N·m (lb·ft) I 78 (58)
3. Radiator under fan shroud
2. Stone guard
1. Dipstick

6A 1-52 ENGINE (V6 3.2L DOHC AND SOHC)
OIL PUMP
7
2
•
4
3
5
Removal steps 1. Timing belt 2. Crankshaft timing pulley
3.
Oil pan
4. Oil pipe and rubber ring 5. Oil strainer and rubber ring
6. Oil cooler assembly
7. Oil pump
Installation steps To install, follow the removal steps in the reverse order.
Fig. 6A1-61
1••1 REMOVAL
1. Timing belt
• See "Timing Belt Removal and Installation".
2. Crankshaft timing pulley
3. Oil pan
• See "Oil Pan Removal and Installation".
4. Oil pipe and rubber ring
5. Oil strainer and rubber ring
6. Oil cooler assembly
7. Oil pump
• Remove sealant from mounting surfaces of oil
pump and cylinder block.
•
Take care not to damage mounting surfaces of
oil pump and cylinder block.
1••1 INSTALLATION
7. Oil pump (Fig. 6A1·62)
rEi1 • Apply sealant (TB-12078 or equivalent) to the
l:!!J oil pump mounting surface as shown in Fig.
6A1-62.
Do not apply sealant to the oil ports.
Fig. 6A1-62
I
~)
•