ISUZU TROOPER 1998 Service Repair Manual

SERVICE INFORMATION 00 Ð 21
Engine Cooling
Starting System
Cooling system
Radiator
Heat radiation capacity
Heat radiation area
Front area
Dry weight
Radiator cap
Valve opening pressure
Coolant capacityCoolant forced circulation
(2 tube in row) Tube type corrugated
318 x 10 (76000)
15.63 (1.454)
0.309 (2.029)
83 (8.5/18.7 )
88.2~117.6 (0.899~1.199/12.78~17.05)
2.8 (2.46/2.96) J/h (kcal/h)
m
2 (ft2 )
m
2 (ft2 )
N(Kg/lb)
kPa(Kg/cm
2psi)
lit (Imp.qt./US qt.)
Coolant pump
Pulley ratioCentrifugal impeller type
1.2
Coolant total capacity
lit (Imp.qt./US qt.)8.6 (7.57/9.09)
6
Rating
Voltage
Output
Time
Number of tooth of pinion
Rotating direction (as viewed from pinion)
Weight (approx.)
No-load characteristics
Voltage/current
Speed
Load characteristics
Voltage/current
Torque
Speed
Locking characteristics
Voltage/current
Torque
Model HITACHI S14-03
V
kw
sec12
30
9
Clockwise
N (kg/lb)
59 (6.0/13.2)
V/A
rpm11/160 or less
3900 or more
V/A
N•m (kg•m/lb•ft)
rpm10.85/300
7.4 (0.75/5.4) or more
2000 or more
V/A
N•m (kg•m/lb•ft)3/1300 or less
26 (2.7/20) or more
11.5/120 or less
4000 or more
7.5/500
13 (1.3/9) or less
1400 or more
2/850 or less
16 (1.6/12) or more2.2 2.8DENSO ADR4G1

00 Ð 22 SERVICE INFORMATION
Charging System
Model (HITACHI)
Rated voltage
Rated outputLR150 – 446
12
50LR180 – 501B
12
80
Rotating direction
(As viewed from pulled)
Pulley effective diameter
Weight (with pump)
Clockwise Clockwise
80 (3.15)
65(6.6 /14.6)
80 (3.15)
76(7.8 /17.2) V
A
mm(in)
N(Kg/lb)

SERVICE INFORMATION 00 Ð 23
SERVICE STANDARD
Engine Mechanicalmm (in)
Parts Items Service standard
Cylinder
HeadCylinder head deck, and
exhaust manifold mating
surface for flatness
Cylinder head height
Hot plug depression
Hot plug installation
pressure0.05 (0.0020) or less
92.0 (3.6220)
—
44000-54000N (4500–5500
kg/9923–12128 lbs)
0.2 (0.0079)
—
0.02 (0.0008)
—Service limit Remarks
Cannot be
reground
Free height
Squareness
Spring tension 48.0 (1.8898)
—
294 (30/66.1) Valve
Spring47.10 (1.8543)
1.7 (0.0669)
257.9 (26.3/57.9) At installed
height
38.9 (1.5) N (lb)
Diameter of Valve stem
Valve and valve guide
clearance
Valve guide upper end
height (Measured from the
Cylinder head upper face)
Valve guide margin
Valve thickness
Valve seat contact
surface angle
Valve seat contact width7.946–7.961
(0.3128–0.3134)
7.921–7.936
(0.3118–0.3124)
0.039–0.071
(0.0015–0.0028)
0.064–0.096
(0.0025–0.0038)
13.0 (0.5118)
1.1 (0.0433)
1.34 (0.0528)
1.38 (0.0543)
45¡
1.7 (0.0669)
2.0 (0.0787) Valve
and
Valve
Guide7.880 (0.3102)
7.850 (0.3091)
0.200 (0.0079)
0.250 (0.0098)
—
1.6 (0.0630)
1.1 (0.0433)
1.1 (0.0433)
—
2.2 (0.0866)
2.5 (0.0984) IN
EX
IN
EX
IN
EX
IN
EX
Curvature — Push rod
0.3 (0.0118)

00 Ð 24 SERVICE INFORMATION
mm (in)
Parts Items Service standardService limit Remarks
End play
Cam height
Journal diameter
Run-out
Camshaft bearing inside
diameter
Camshaft bearing clearance0.08 (0.0031)
42.02 (1.6543)
49.945-49.975
(1.9663-1.9675)
0.02 (0.0008) or less
50.000–50.030
(1.9685–1.9697)
0.025-0.085
(0.0010-0.0033) Camshaft
0.2 (0.0079)
41.65 (1.6398)
49.60 (1.9528)
0.10 (0.0039)
50.08 (1.9716)
0.12 (0.0047)
Outside diameter
Clearance between
tappet and cylinder
body12.97-12.99
(0.5106-0.5114)
0.03 (0.0012) Tappet
12.95 (0.5098)
0.10 (0.0039)
Rocker arm shaft outside
diameter
Rocker arm inside
diameter
Clearance between
rocker arm and rocker
arm shaft
Rocker arm shaft runout18.98-19.00
(0.7472-0.7480)
19.01-19.03
(0.7484-0.7492)
0.01-0.05
(0.00039-0.00197)
— Rocker arm
Assembly18.90 (0.7441)
19.10 (0.7520)
0.20 (0.00787)
0.30 (0.0118)
Oil clearance
Body and gear
Body cover and gear0.14 (0.0055)
0.06 (0.0024) Oil pump
0.20 (0.0079)
0.15 (0.0059)
Thrust clearance
Main bearing clearance
(Between main bearing
and Crankshaft)
Crankshaft runout
Main journal diameter
Crank pin diameter0.10 (0.0039)
0.031-0.063
(0.0012-0.0025)
0.05 (0.0020) or less
69.917-69.932
(2.7526-2.7532)
52.915-52.930
(2.0833-2.0839) Crankshaft
0.30 (0.0118)
0.11 (0.0043)
0.08 (0.0031)
69.91 (2.7524)
52.90 (2.0827)Cannot be
reground
Uneven wear
limit 0.05
(0.002)
Uneven wear
limit 0.08
(0.0031)

SERVICE INFORMATION 00 Ð 25
mm (in)
Parts Items Service standardService limit Remarks
1st/2nd
Oil
1st/2nd
Oil
Bend
Twist
Piston diameter
Piston Clearance
(Between piston and
Cylinder liner)
Piston ring gap
Piston ring clearance
Piston pin outside diameter
Clearance between
connecting rod and
piston pin
Clearance between
piston and piston pin
Connecting rod
alignment
Connecting rod thrust
clearance
Clearance between
crank pin and connecting
rod95.365-95.404
(3.7545-3.7561)
0.047-0.065
(0.0019-0.0026)
0.20-0.35
(0.0079-0.0138)
0.10-0.30
(0.0039-0.0118)
0.05-0.09
(0.0020-0.0035)
0.03-0.07
(0.0012-0.0028)
33.995-34.000
(1.3384-1.3386)
0.008-0.020
(0.0003-0.0008)
0.002-0.015
(0.00008-0.0006)
0.08(0.0031) or less
0.05(0.0020) or less
0.230 (0.0091)
0.029-0.083
(0.0011-0.0033) Piston,
Piston pin,
Piston ring
and
Connecting
rod —
—
1.5 (0.0591)
1.5 (0.0591)
0.15 (0.0059)
0.15 (0.0059)
33.970 (1.3374)
0.05 (0.0020)
0.04 (0.0016)
0.20 (0.0079)
0.15 (0.0059)
0.35 (0.0138)
0.100 (0.0039)Per 100 (3.937)
Per 100 (3.937)
Warpage
(Upper surface of the
cylinder block)
Cylinder bore diameter —
97.001-97.040
(3.8189-3.8205) Cylinder
Block 0.20 (0.0079)

00 Ð 26 SERVICE INFORMATION
Engine Cooling
mm (in)
mm (in)
Parts Items Service standardService limit Remarks
Cylinder liner
projection
Cylinder liner outside
diameter0.0-0.1
(0.00-0.0039)
97.011-97.050
(3.8193-3.8209) Cylinder
Block
(cont’ d)
Parts Items Service standardService limit Remarks
Valve opening
temperature
Valve full open
temperature and lift82¡C
(180¡F)
More than 10 (0.39)
at 95¡C (203¡F) Thermostat
Valve opening pressure 88.2 ~ 117.6kpa
(0.899 ~ 1.199kg/cm2/
12.8 ~ 17.0psi) Radiator
cap
Tension (Slackness)
AC generator & fan
pulley drive belt
A/C Compressor drive
belt
P/S pump drive beltNew belt
8-12 (0.31-0.47)
Used belt
8-12 (0.31-0.47)
New belt
7-10 (0.28-0.39)
Used belt
5-8 (0.2-0.31)
New belt
13-16 (0.51-0.63)
Used belt
13-16 (0.51-0.63) Drive belt

SERVICE INFORMATION 00 Ð 27
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the front left hand side of
the cylinder body.
AIR CLEANER
Oil Wetted (Viscous) Type Paper Element (Australia only)
The air cleaner has an oil wetted paper element. No servic-
ing is required until the replacement interval is reached.
Never attempt to clean the element, no matter how dirty it
may appear. The element is designed to provide normal
filtering efficiency until it becomes due for replacement.
Refer to the Item ÒService and MaintenanceÓ in the OwnerÕs
and DriverÕs Manual for general service information.
Dry Type Paper Element
Element cleaning procedures will vary according to the
condition of the element.
Dust Fouled Elemant
Rotate the element with your hand while applying com-
pressed air to the inside of the element. This will blow the
dust free.
392 - 490 (4-5/57-71)
Compressed air pressure
Kpa (Kg/cm2 / Psi)
CAUTION
Do not bang the element against another object in an
attempt to clean it. Damage to the element will result.
Carbon and Dust Fouled Element
1. Prepare a cleaning solution of Isuzu Genuine Element
Cleaner (Donaldson D1400) diluted with water.
2. Submerge the element in the solution for twenty min-
utes.

00 Ð 28 SERVICE INFORMATION
3. Remove the element from the solution and rinse it well
with running water.
Water pressure must not exceed 274 Kpa (2.8 kg/cm
2/40
Psi)
4. Dry the element in a well ventilated area.
An electric fan will hasten drying.
NOTE:
Do not use compressed air or an open flame to dry the
element quickly. Damage to the element will result.
It will usually take two or three days for the element to dry
completely. Therefore, it is a good idea to have a spare on
hand to use in the interim.
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Loosen the drain plug to drain the engine oil.
2. Wait a few minutes and then retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with the filter wrench.
4. Clean the oil cooler fitting face.
This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional 1
and 1/4 turns.
Filter Wrench: 5-8840-0200-0
8. Check the engine oil level and replenish to the specified
level if required.
0.7 (0.62/0.74)
lit(Imp qt / US qt) Replenishment Engine Oil
9. Start the engine and check for oil leakage from the main
oil filter.

SERVICE INFORMATION 00 Ð 29
FUEL SYSTEM
Fuel Filter
Replacement Procedure
1. Loosen the used fuel filter by turning it counterclock-
wise with the filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
2. Remove the level sensor from the filter by turning it
counterclockwise with a wrench.
3. Install the level sensor to the new fuel filter with a
wrench.
5. Apply a light coat of engine oil to the O-ring.
6. Turn in the fuel filter until the sealing face comes in
contact with the O-ring.
7. Turn in the fuel filter an additional 2/3 of a turn with a
filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
8. Loosen the bleeder plug on the injection pump overflow
valve.
9. Operate the priming pump until fuel begins to flow from
the fuel filter.
10. Retighten the bleeder plug.
11. Operate the priming pump several times and check for
fuel leakage.
NOTE:
The use of an ISUZU genuine fuel filter is strongly recom-
mended.
13 (1.3/9)
N·m (Kg·m/lb·ft) Level Sensor Torque
4. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.

00 Ð 30 SERVICE INFORMATION
Fuel Filter Water Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water separa-
tor with the following procedure.
1. Find a safe place to park the vehicle.
2. Open the engine hood and place a container (Approxi-
mately 0.2 liter capacity) at the end of the vinyl hose
beneath the drain plug on the separator.
3. Loosen the drain plug by turning it counterclockwise
(Approximately 5 turns) and operate the priming pump
up and down about 10 times until water is drained
approximately 0.1 liter.
4. After draining, securely tighten the drain plug by turn-
ing it clockwise and operate the priming pump manu-
ally up and down several times.
5. After starting the engine, check to see that there is no
fuel leak from the drain plug.
Also check to see that the fuel filter water indicator light
has turned off.
If water separator requires frequent draining, have the
fuel tank drained for removal of water at your Isuzu
Dealer.
Air Bleeding
1. Loosen the bleeder screw on the injection pump over-
flow valve.
2. Operate the priming pump until fuel mixed with foam
flows from the bleeder screw.
3. Tighten the bleeder screw.
4. Operate the priming pump several times and check for
fuel leakage.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the ÒMINÓ line, carefully check
the cooling system for leakage. Then add enough coolant to
bring the level up to the ÒMAXÓ line.
NOTE:
Do not overfill the reserve tank.