drain bolt ISUZU TROOPER 1998 Service Owner's Guide

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 11
TURBOCHARGER (4JG2-T only)
REMOVAL
Preparation
·Space stand and remove right front tire
·Remove battery
·Drain coolant
1. Air Cleaner Cover & Air Duct
·Disconnect connecting rubbers and stay fixing
bolts.
2. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler removal steps in this section.
3. Power Steering (P/S) Pump Drive Belts
·Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belt.
4. Engine Ground Cable

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 15
TIMING GEAR
REMOVAL
Preparation:
·Disconnect battery ground cable.
·Drain coolant.
1. P/S Pump Drive Belt
·Loosen P/S pump mounting bolt and adjust bolt,
and remove the drive belt.
2. AC Generator Drive Belt
·Loosen AC Generator mounting bolt (under side)
and adjust plate lock bolt, and remove the drive
belt.
3. Cooling Fan Assembly
·Remove clamp nut, and remove cooling fan asm,
distant pipe, and fan pulley.
4. Crankshaft Damper Pulley
5. Upper Noise Shield Cover
6. Lower Noise Shield Cover
7. Noise Cover Spacer.
8. Timing Gear Case Cover
9. Oil Pipe
10. Idler Gear ÒBÓ and Shaft
1) Measure the camshaft timing gear backlash and the
crenkshaft timing gear backlash before removing the
idler gear.

4JG2-NA/4JG2-TURBO ENGINE 6A 2Ð 27
REMOVAL
Preparation
·Remove battery. (two batteries for cold area)
·Disconnect window washer hose, and remove
engine hood.
·Drain coolant.
·Space stand and front right tire.
1. Radiator Hose : Upper
·Disconnect upper radiator hose from engine side.
2. Air Cleaner Cover & Air Duct
3. Intercooler Assembly (4JG2-T Only)
·(Refer to intercooler removal steps in this section)
4. Oil Level Gauge Guide Tube
5. P/S Pump
·Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belts.
·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.
6. 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 line on battery carrier.
7. Water Hose; CSD
·Disconnect CSD water hoses from heater hose
side.
8. Engine Harness
·Disconnect five harness connectors from units on
thermostat housing.
9. Heater Hose: Rear Side
·Disconnect heater hose from heater pipe.
10. Water Bypass Hose
·Disconnect water bypass hose from water pump.
11. Water Inlet Hose: Turbo (4JG2-T Only)
·Disconnect from water outlet pipe of engine.
12 Water Outlet Hose: Turbo (4JG2-T Only)
·Disconnect from water inlet pipe of engine.
13 Oil Feed Pipe: Turbo (4JG2-T Only)
·Remove two joint bolts (from turbocharger and
cylinder block) and oil feed pipe.
14. Oil Return Pipe Fixing Nut (4JG2-T Only)
·Remove oil return pipe fixing nut from cylinder
block.
15. Oil Cooler Hose

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 31
CRANKCASE
REMOVAL
Preparation
·Disconnect battery ground cable.
·Lift up car.
·Drain engine oil.
NOTE
·Install drain plug with new gasket.
1. Transmission Housing Bolt
·Remove six fixing bolts from under side of hous-
ing.
2. Oil Return Pipe: Turbo (4JG2 -T only)
·Remove return pipe fixing nuts and set return pipe
frange from stud on crankcase.
3. Oil Pipe Clip Bolt: Vaccum Pump
4. Oil Level Gauge Guide Tube
·Remove two guide tube stay fixing bolts.
·Disconnect blow by hose and remove oil level
gauge guide tube.

6A2 Ð 34 4JG2-NA/4JG2-TURBO ENGINE
OIL COOLER
REMOVAL
Preparation
·Disconnect battery ground cable
·Drain coolant
1. Air Cleaner Cover & Air Duct
2. Intercooler Assembly (4JG2-T Only)
·Refer to intercooler removal steps in this section
3. Front Exh. Pipe
·Disconnect front exhaust pipe from engine side
and intermediate pipe.
4. Heat Protector (4JG2-T Only)
5. Exh. Adapter (4JG2-T Only)
6. Oil Cooler
·Disconnect water inlet and outlet hose.
·Remove fixing bolts and oil cooler.
·Put rag to beneath side of oil cooler to prevent oil
leaking.

6A2 Ð 36 4JG2-NA/4JG2-TURBO ENGINE
OIL PUMP ASSEMBLY
REMOVAL
Preparation
·Disconnect battery ground cable.
·Lift up car.
·Drain engine oil.
NOTE
·Install drain plug with new washer.
1. Crankcase
·Refer to crankcase removal steps in this section
2. Oil Pump Assembly
·Remove oil pump asm from cylinder block.
INSTALLATION
·Prepare a solution of 80% engine oil and 20% molyb-
denum disulfide.
·Apply and ample coat of the solution to the teeth of
the oil pump pinion.
2. Oil Pump Assembly
·Apply engine oil to oil pipe o-ring and insert the
o-ring in o-ring hold on cylinder block.
·Install oil pump asm with oil pipe in cylinder block
and tighten fixing bolts to the specified torque.
19 (1.9/14)N·m(Kg·m/lb·ft)
·Tighten sleeve nut to the specified torque.
25 (2.5/18)N·m(Kg·m/lb·ft)
1. Crankcase
·Refer to crankcase installation steps in this section

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

FUEL SYSTEM 6C Ð 15
REMOVAL
Preparation:
·Disconnect battery ground cable.
·Drain coolant.
1. Air Cleaner Cover & Air Duct
2. Intercooler Assembly (4JG2-T ONLY)
· Refer to Intercooler Assembly removal.
3. Radiator Assembly
·Disconnect upper and lower hoses on the engine
side.
4. Cooling Fan Assembly
·Remove cooling fan asm and remove fan pulley
and spacer.
5. P/S Pump Drive Belt
·Loosen P/S pump lock bolt and adjust bolt remove
two drive belts.
6. AC Generator Drive Belt
·Loosen AC generator mounting bolt (under side)
and adjust, bolt and remove drive belt.
7. Timing Gear
·Refer to Timing Gear Removal
·Remove the loosened nut and fixing bolt and
remove the timing gear.
8.Fuel Filter Assembly
9. Injection Pump Harness
·Remove tachometer sensor, throttle sensor, and
fuel cut solenoid, harness.
10. Fuel Hose & CSD Hose
·Disconnect inlet hose and outlet hose and keep
hose end up to prevent fuel from coming out.
·Disconnect CSD hose.
11. Injection Pump Control Cable
12. Injection Pipe
·Release pipe clip.
·Remove the flare nut on the pump side.
·Remove the flare nut on the injection nozzle side,
and remove the injection pipe.
CAUTION
·Be sure to plug the injection nozzle holder and
delivery holder to prevent the entry of foreign
matter.
13. Injection Pump Assembly
·Remove pump mounting nut
·Loosen injection pump rear bracket adjuster lock
bolt.
·Remove the mounting bolt on the engine side, and
pull out the pump behind the engine.

6C Ð 18 FUEL SYSTEM
FUEL TANK
4. Fuel tank wiring connector
5. Evapo fuel hose
6. Fuel hose and fuel return hose
7. Fuel tank
Installation Steps
To install, follow the removal steps in the
reverse order.
Removal Steps
1. Inner liner
2. Fuel filler hose and breather hose
3. Under cover
REMOVAL
Preparation:
·Disconnect battery ground cable.
·Loosen fuel filler cap.
·Drain fuel.
·Tighten drain plug to the specified torque after drain-
ing fuel.
20 (2.0/14)
N·m (Kg·m/lb·ft)
1. Inner Liner
·Remove inner liner of wheel arch on rear right side.
2. Fuel Filler Hose and Air Breather Hose
3. Under Cover
·Remove undercover fixing bolts on both sides.
4. Fuel Tank Wiring Connector
·Disconnect two connectors on front right side of tank.
5. Evapo Fuel Hose
6. Fuel Hose and Fuel Return Hose
7. Fuel Tank
·Remove fuel tank fixing bolts on both sides.