Remove engine ISUZU TROOPER 1998 Service Repair Manual

6E±303 ENGINE DRIVEABILITY AND EMISSIONS
4. Check the transfer case oil level. Add fluid if
necessary.
5. Connect the negative battery cable.
Air Cleaner/Air Filter
Removal Procedure
1. Loosen the clamp between the air cleaner lid and the
mass air flow sensor.
2. Release the four latches securing the lid to the air
cleaner housing.
3. Remove the air cleaner lid.
TS23973
4. Remove the air filter element.
TS23794
5. Remove the retaining bolts and the air cleaner
housing from the vehicle.
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Installation Procedure
1. Install the air cleaner housing in the vehicle with the
retaining bolts.
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6E±304
ENGINE DRIVEABILITY AND EMISSIONS
2. Install the air filter element in the air cleaner housing.
TS23794
3. Install the air cleaner lid on the MAF sensor and the air
cleaner housing.
TS23973
4. Tighten the clamp and secure the four latches
between the lid and the air cleaner housing.
Idle Air Control (IAC) Valve
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the IAC electrical connector.
3. Remove the bolts and the IAC valve from the throttle
body.
NOTE: Do not clean the IAC valve by soaking it in
solvent. The valve will be damaged as a result.
TS23745
Cleaning, Inspection, and
Measurement Procedure

Clean the IAC valve O-ring sealing surface, pintle
valve seat and air passage.
± Use carburetor cleaner and a parts cleaning brush to
remove carbon deposits. Do not use a cleaner that
contains methyl ethyl ketone. This is an extremely
strong solvent and not necessary for this type of
deposit.
± Shiny spots on the pintle are normal and do not
indicate misalignment or a bent pintle shaft.
± If the air passage has heavy deposits, remove the
throttle body for complete cleaning.
TS23746

Inspect the IAC valve O-ring for cuts, cracks, or
distortion. Replace the O-ring if damaged.

6E±305 ENGINE DRIVEABILITY AND EMISSIONS

In order to install a new IAC valve, measure the
distance between the tip of the pintle and the
mounting flange. If that measurement is 28 mm (1.1
in.) or less, the valve needs no adjustment. If the
measurement is greater than 28 mm (1.1 in.), apply
finger pressure and retract the valve. The force
required to retract the pintle on a new valve will not
damage the valve, shaft, or pintle.
NOTE: Do not push or pull on the IAC valve pintle on IAC
valves that have been in service. The force required to
move the pintle may damage it.
IMPORTANT:Use an identical replacement part in
order to replace a valve. IAC valve pintle shape and
diameter are designed for the specific application.
TS23746
Installation Procedure
1. Install the IAC valve on the throttle body with the bolts.
Tighten

Tighten the bolts to 1 N´m (9 lb in.).
TS23745
2. Connect the IAC valve electrical connector.
3. Install the negative battery cable.
Common Chamber
Removal and Installation Procedure
Refer to Common Chamber in Engine Mechanical.
Accelerator Cable Assembly
Removal Procedure
1. Remove the engine cover.
2. Loosen the adjusting nut on the cable bracket
mounting on the common chamber.
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3. Remove the accelerator control cable (on the throttle
valve end).
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6E±306
ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the accelerator control cable (on the
accelerator pedal end).
TS23982
5. Remove the grommet.
6. Remove the accelerator control cable.
TS23983
Inspection Procedure
Check the following items, and replace the control cable if
any abnormality is found:

The control cable should move smoothly.

The control cable should not be bent or kinked.

The control cable should be free of damage and
corrosion.
Installation Procedure
1. Install the accelerator control cable.
TS23983
2. Install the grommet.
3. Install the accelerator control cable (on the
accelerator pedal end).
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6E±308
ENGINE DRIVEABILITY AND EMISSIONS
Accelerator Pedal Replacement
Removal Procedure
1. Disconnect the cruise control cable from the
accelerator pedal assembly.
TS24053
2. Disconnect the accelerator pedal control cable from
the accelerator pedal assembly.
TS24054
3. Disconnect the wiring harness from the kick-down
switch.
TS24038
4. Remove the two screws from the accelerator pedal
assembly.
TS24055
5. Remove the accelerator pedal assembly from the
bulkhead.

6E±310
ENGINE DRIVEABILITY AND EMISSIONS
Pedal Stroke Adjustment Procedure
1. Loosen the jam nut and rotate the kick-down switch
counterclockwise.
TS24039
2. Fully depress the pedal and hold it by hand. Rotate
the switch clockwise until the switch clicks.
3. Rotate the switch 1/2 turn further and lock it in this
position by tightening the jam nut.
TS24040
4. Step on the accelerator pedal and make sure there is
a clicking sound at the full-stroke position.
Fuel Filter Cap
General Description
The fuel filler cap includes a vacuum valve and a pressure
valve.If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
prevent damage to the tank at the EGR valve.
TS23767
Inspection Procedure
NOTE: Replace the fuel filler cap with the same type of
filler cap that was originally installed on the vehicle.

Check the seal ring in the filler cap for any abnormality
and for seal condition.

Replace the filler cap if any abnormality is found.
Fuel Filter
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the fuel filler cap.
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6E±311 ENGINE DRIVEABILITY AND EMISSIONS
3. Disconnect the fuel line from the fuel filter on the
engine side.
4. Disconnect the fuel line from the fuel filter on the fuel
tank side.
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5. Remove the bolt on the fuel filter holder.
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6. Remove the fuel filter.
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Inspection Procedure
1. Replace the fuel filter when the following occur:

Fuel leaks from the fuel filter body.

The fuel filter body is damaged.

The fuel filter is clogged with dirt or sediment.
2. If the drain hole is clogged, clean the drain.
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6E±313 ENGINE DRIVEABILITY AND EMISSIONS
Fuel Gauge Unit
Removal Procedure
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank.
Tighten

Tighten the drain plug to 20 N´m (14 lb ft.).
TS22907
4. Disconnect the wiring connector from the fuel gauge
unit.
TS23771
5. Remove the fuel gauge unit retaining screws.
6. Remove the fuel gauge unit.

Cover or plug the fuel tank to prevent dust, dirt, or
debris from entering the tank.
TS22911
Installation Procedure
1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.
TS22911

6E±314
ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the wiring connector to the fuel gauge unit.
TS23771
4. Fill the fuel tank with fuel.

Tighten the fuel filler cap.

Check for leaks at the fuel gauge unit gasket.
5. Connect the negative battery cable.
Fuel Injectors
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil may
be contaminated with fuel. Check the oil for signs of
contamination and change the oil and the filter if
necessary.
NOTE: Use care in removing the fuel injectors in order to
prevent damage to the fuel injector electrical connector
pins or the fuel injector nozzles. The fuel injector is an
electrical component and should not be immersed in any
type of cleaner as this may damage the fuel injector.
IMPORTANT:Fuel injectors are serviced as a complete
assembly only.
1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to
Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to
Fuel Rail.
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4. Remove the injector retainer clip.
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5. Remove the fuel injector assembly.
6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .
Inspection Procedure
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.

6E±315 ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.
3. Install the fuel injector on the fuel rail.
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4. Use new fuel injector retainer clips to retain the fuel
injector to the fuel rail.
5. Coat the end of the fuel injector with engine oil.
6. Install the fuel rail. Refer to
Fuel Rail.
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7. Install the upper intake manifold. Refer to Common
Chamber in Engine Mechanical.
8. Install the engine cover.
9. Connect the negative battery cable.
Fuel Pressure Regulator
Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before disconnecting the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
NOTE: Compressed air must never be used to test or
clean a fuel pressure regulator, as damage to the fuel
pressure regulator may result.
NOTE: To prevent damage to the fuel pressure regulator,
do not immerse the pressure regulator in solvent.
1. Depressurize the fuel system. Refer to
Fuel Pressure
Relief Procedure
.
2. Disconnect the negative battery cable.
3. Remove the fuel pump relay. Refer to
Fuel Pump
Relay
.
4. Remove the pressure regulator hose from the fuel
pressure regulator.
014RW110