Remove engine ISUZU TROOPER 1998 Service Repair Manual

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 41
19 (1.9/14)N·m(Kg·m/lb·ft)
·After tightening the bolts, make sure that the
crankshaft rotates smoothly.
167 (17.0/123)N·m(Kg·m/lb·ft)
13. Connecting Rod Caps
·The cap number must be same as connecting rod
number.
·Apply engine oil to the thread and sealing surface
of each nut.
·Tighten nuts to the specified torque.
·After tightening the nuts, make sure that the
crankshaft rotates smoothly.
12. Rear Plate
·Tighten bolts to the specified torque.
82 (80/61)N·m(Kg·m/lb·ft)
11. Flywheel
·Tighten bolts to the specified torque.
118 (12.0/87)N·m(Kg·m/lb·ft)
10. Gear Case
·Tighten fixing bolts to the specified torque.
19 (1.9/14)N·m(Kg·m/lb·ft)
9. Crankcase
·Remove oil from oil pan mounting surface, and
dry the surface.
·Apply a proper wide bead of sealant (TB1207C or
equivalent) to the crankcase mounting surface.
The bead must be continuous.
·Crankcase must be installed within 5 minutes
after sealant application.
·Tighten fixing bolts and nuts to the specified
torque.
Bolts
1st step 29 (3.0/22) 2nd step 45° – 60°N·m(Kg·m/lb·ft)

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 45
FRONT OIL SEAL
REMOVAL
1. Crankshaft Damper Pulley
2. Timing Gear Case Cover Assembly
3. Front Oil Seal
·Remove crankshaft front oil seal using suitable size
box wrench for push the oil seal from inside of
timing gear case cover.
INSTALLATION
3. Front Oil Seal
·Use the installer to install the front oil seal 1 to the
gear case cover 2.
Oil Seal Installer: 5-8840-2061-0
Note the oil seal installation depth 3 shown in the
illustration.
Depth 3 = 1 mm (0.039 in).
2. Timing Gear Case Cover Assembly
1) Align the timing gear case cover with the timing
gear case dowel pin then install the timing gear case
cover.
2) Tighten the timing gear case cover bolts to the
specified torque.
8 (0.8/69)N·m(Kg·m/lb·in)
1. Crankshaft Damper Pulley

6A2 Ð 46 4JG2-NA/4JG2-TURBO ENGINE
REAR OIL SEAL
REMOVAL
1. Transmission Assembly
·Refer to ÒTransmissionÓ removal in section 7.
2. Flywheel
3. Rear Oil Seal
·With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover : 5-8840-2362-0
INSTALLATION
3. Rear Oil Seal
8. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear and
section with 2 bolts.
2) Insert the oil seal into the peripheral section of the
adapter,
3) Insert the sleeve into the adapter section, and 1)
tighten it with a bolt (M12 x 1.75L = 70) until the
adapter section hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the dimension of
the oil seal section.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-0

6A2 Ð 48 4JG2-NA/4JG2-TURBO ENGINE
ENGINE ASSEMBLY
REMOVAL
Preparation
·Space stands and removal front tires.
·Removal battery. (two batteries for cold area)
·Drain coolant.
·Disconnect window washer hose and remove engine
hood.
1. Radiator Hose
·Disconnect upper and lower hoses from engine
side.
2. Fan Shroud
·Disengage clips and remove upper and lower fan
shrouds.

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 49
3. Cooling Fan Assembly
·Remove cooling fan asm fixing nuts, cooling fan
asm, fan pulley and center.
4. Radiator Assembly
·Remove bracket and radiator asm.
5. Air Cleaner Cover & Air Duct
6. Intercooler Assembly (4JG2 -T only)
·(Refer to Intercooler removal steps in this section)
7. P/S Pump Drive Belts
·Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belts.
8. P/S Pump Assembly
·Remove two fixing bolts (front side), a fixing nut
(rear side) and support P/S pump asm with oil
hoses by tying to body side.
9. Engine Ground Cable
·Disconnect ground cable from A/C compressor
bracket.
10. AC Generator Harness
·Disconnect B terminal and harness connector
from AC generator.
11. A/C Compressor Assembly
·Remove A/C compressor fixing bolt (rear under
side of compressor) by using a long extension bar
at under side of wheel arch.
·Disconnect magnetic clutch harness connector.
·Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor asm with
pipe lines on battery carrier.
12. Vacuum Hose: Vacuum Pump
·Disconnect vacuum hose from vacuum pump.
13. Starter Harness
·Disconnect B terminal and put cable harness close
to chassis side.
·Disconnect S terminal connector.
14. Engine Harness.
·Disconnect engine harness close to engine side.
15. Accelerater Cable
·Loosen locking nut at bracket and disconnect
accelerater cable from injection pump control
lever.
16. Fuel Hoses
·Disconnect fuel hoses from injection pump side
and take care not to spill fuel and enter dust.
17. Engine Ground Cable
·Disconnect ground cable from left rear side of
timing gear case.

6A2 Ð 50 4JG2-NA/4JG2-TURBO ENGINE
18. Vacuum Hose : Vacuum Tank
·Disconnect vacuum hose from vacuum pump
side.
19. Glow Plug Harness
20. Transmission Assembly
·Install special tools (engine hangers) in front right
and left rear sides of cylinder head.
·Front right side; use the ground cable fixing bolt
on A/C compressor bracket.
·Left rear side; fix hanger together with oil cooler
hose clip.
Engine hanger: 5-8840-2032-0
·Left engine carefully by using hoist.
21. Engine Mounting
·Remove fixing bolts (both left and right side)
using extension bar and box wrench at under side
of wheel arches.
22. Engine Assembly
·Install special tools (engine hangers) in left rear
and front right sides of cylinder head.
·Lift engine carefully by using hoist.
·Lift front part of engine higher than rear part of it.
·Take out engine asm taking care not to damage
full pipes, brake pipes and etc.
INSTALLATION
22. Engine Assembly
·Position engine mountings by using hoist.
21. Engine Mounting
·After all fixing bolts (left: two bolts, rights: two
bolts) were inserted to every holes, and engine
asm and tighten fixing bolts to the specified
torque.
40 (4.1/30)N·m(Kg·m/lb·ft)
20. Transmission Assembly
·Refer to transmission installation steps
in section 7.
19. Glow Plug Harness
18 Vacuum Hose: Vacuum Tank
17. Engine Ground Cable
16. Fuel Hose
15. Accelerator Cable
·Refer to accelerater cable installation steps in
section 6C.

ENGINE COOLING 6B Ð 5
ON-VEHICLE SERVICE
WATER PUMP
REMOVAL
Preparation
·Drain coolant.
1. P/S pump Drive Belts
·Loosen P/S pump mounting bolt, loosen adjust
bolts and remove the drive belts.
2. AC Generator Drive Belt
·Loosen AC Generator mounting bolt (bottom
side), adjust plate lock bolt, and remove the drive
belt.
3. Cooling Fan Assembly
·Remove lock nut and take out cooling fan
assembly, distance piece, and fan pulley.
4. Crankshaft Damper Pulley.
5. Gear Case Cover.
6. Water Pump Assembly
7. O-ring
INSPECTION
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection. Should any
of the following problems occur, the entire water pump
assembly must be replaced.
·Cracks in the coolant pump body
·Coolant leakage from the seal unit
·Play or abnormal noise in the bearing
·Cracks or corrosion in the impeller

ENGINE COOLING 6B Ð 7
THERMOSTAT
REMOVAL
Preparation
·Disconnect battery ground cable.
·Drain coolant from the radiator and engine.
1. Water Hose; Turbocharger (4JG2-T Only)
2. Outlet Pipe
·Remove mounting bolt and remove outlet pipe
together with radiator hose.
3. Gasket
4. Thermostat
INSPECTION
Submerge the thermostat assembly in the water.
Place wooden blocks on the bottom of the water
container.
Not to directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
·Make sure that primary valve begins to open at the
specified temperature.
82 (180 )
°C (°F) Valve Opening Temperature

ENGINE COOLING 6B Ð 9
RADIATOR
REMOVAL
Preparation
·Disconnect battery ground cable.
·Loosen drain plug to drain coolant.
1. Radiator Hose
·Disconnect lower hose and upper hose from the
engine.
2. Fan Guide Lower
·Remove clips on both sides and the bottom lock.
3. Reservoir Tank Hose
·Disconnect the hose from radiator.
4. Bracket
5. Radiator Assembly
·Remove upward the radiator assembly with hose,
taking care not to damage the radiator core by fan
blade.
·Remove cushion rubbers on both sides of the
bottom.
INSPECTION
Radiator Cap
·Measure the valve opening pressure with the radiator
cap tester. Replace the radiator cap if it exceeds the
standard.
Check the condition of negative pressure valve in the
center of valve seat side of the cap. If the valve seat
does not move smoothly due to rust or dust, clean or
replace the radiator cap.
Valve opening pressure
93.3 – 122.7 (0.95 – 1.25/13.5 – 17.8)kPa(Kg/cm2 / psi)

6B Ð 10 ENGINE COOLING
Radiator Core
·Deformed radiator fins could reduce radiation effects,
resulting in overheat. Straighten the fins. In such a
case, take care not to damage the fin roots.
·Remove dust and other foreign materials.
Flushing the Radiator
·Wash the inside of radiator and the coolant passage
with water and neutral detergent. Remove all scales
and rust.
Checking for Coolant Leakage
·Check the cooling system for leakage with the radiator
cap tester by applying 196.0kPa (28.4 psi) air pressure
from filler neck to inside the radiator.
INSTALLATION
5. Radiator Assembly
·Install cushion rubbers on both sides of radiator
bottom.
·Install radiator assembly with hose, taking care not
to damage the radiator core by a fan blade.
4. Bracket
·Support the radiator upper tank with the bracket
and fix the radiator.
3. Reserve Tank Hose
2. Fan Guide, Lower
1. Radiator Hose
·Connect inlet hose and outlet hose to the engine.
·Connect battery ground cable.
·Pour coolant
·Pour coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
·Start engine to warm up, and check for coolant
level. Replenish coolant if it does not reach the
radiator filler neck, and tighten the cap completely.