wheel bolts ISUZU TROOPER 1998 Service Service Manual

6A±74
ENGINE MECHANICAL
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin

Apply engine oil to the oil seal lip.

Align the cylinder block dowel pin holes with the rear
retainer dowel pins.

Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
Torque: 18 N´m (1.8 Kg´m/13 lb ft)
NOTE: Be very careful not to disengage the oil seal garter
spring during installation of the rear retainer.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip and
install the oil seal using 5±8840±2286±0 oil seal
installer.
015RW001
015RS017
3. Flywheel (9)
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Hold the crankshaft to prevent from rotating then
install the bolts in the order shown to the specified
torque.
Torque: 54 N´m (5.5 Kg´m/40 lb ft)
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS018

6A±85
ENGINE MECHANICAL
Cylinder Block
Cylinder Block and Associated Parts
012RW010
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Pump Assembly
(7) Cylinder Block Side Bolts(8) Oil Gallery
(9) Piston and Connecting Rod Assembly
(10) Flywheel
(11) Rear Oil Seal Retainer Assembly
(12) Main Bearing Cap
(13) Crankshaft
(14) Cylinder Block
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.

6A±88
ENGINE MECHANICAL
015RW001
4. Install flywheel
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
Torque: 54 N´m (5.5 Kg´m/40 lb ft)
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
015RS018
5. Install piston and connecting rod assembly.

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
NOTE: Do not apply engine oil to the bearing back faces.
Check to see that the piston ring end gaps are
correctly positioned.
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark

Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.

The front marks (1) must be facing the front of the
engine.
015RS020
6. Install oil gallery and tighten the bolts in 2 steps in the
order shown.
1st step : 29 N´m (3.0 Kg´m/22 lb ft)
2nd step : 55
~ 65

6C±7
ENGINE FUEL
Fuel Pump Relay
General Description
In order to control the FP operation, the FP relay is
provided. When the starter switch is turned to ªONº
position, the FP relay operates the FP for 2 seconds.When it is turned to ªSTARTº position, the Power Train
Control Module (PCM) receives the reference pulse from
the Ignition Control Module and it operates the relay,
again causing the FP to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
035RW048
Legend
(1) Fender Liner
(2) Fuel Filler Hose and Air Breather Hose and
Evapo Hose
(3) Undercover(4) Fuel Tank Wiring Connector
(5) Evapo Fuel Hose
(6) Fuel Feed Tube and Fuel Return
Tube/Quick±Connect Fittings
(7) Fuel Tank
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section ªDriveability and Emissionº.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 N´m (2.0 Kg´m/14 lb ft) Ð M8
4. Remove fender liner (1) of wheel well on rear right
side.
5. Fuel filler hose, air breather hose and evapo hose (2).
6. Remove undercover fixing bolts on both sides and
remove under cover(3).

6C±8
ENGINE FUEL
7. Disconnect two fuel tank wiring connectors(4) on
front right side of tank.
8. Disconnect evapo fuel hose(5).
9. Disconnect fuel feed tube and fuel return tube(6).
NOTE: Handling of the fuel tube, be sure to refer ªFuel
Tube/Quick±Connect Fittingsº in this section.
10. Remove fuel tank fixing bolts on both sides and
remove fuel tank(7).
Installation
1. Install fuel tank(7).

Place a flange on right side of tank on the bracket.
Install a flange on left side on the bracket from the
bottom, and tighten bolts to the specified torque.
Torque: 36 N´m (3.7 Kg´m/27 lb ft)
2. Connect fuel feed tube and fuel return tube(6).
3. Connect evapo fuel hose(5).
4. Connect fuel tank wiring connector(4).
5. Install undercover(3).
6. Connect fuel filler hose, air breather hose and evapo
hose(2).
7. Install fender liner(1).

Mount fender liner to the wheel well.

Fill the tank with fuel and tighten fuel filler cap.

Connect battery ground cable.
Fuel Tube / Quick ± Connect Fittings
Precautions

Lighting of Fires Prohibited.

Keep flames away from your work area to prevent the
inflammable from catching fire.

Disconnect the battery negative cable to prevent
shorting during work.

When welding or conducting other heat-generating
work on other parts, be sure to provide pretreatment
to protect the piping system from thermal damage or
spattering.
Cautions During Work
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
The piping wet with battery electrolyte cannot be used.
Be careful not to give a bending or twisting force to the
piping during the work. If deformed, replace with a new
piping.
Removal
1. Open the fuel cap to relieve the fuel pressure in the
tank.
If the fuel quick-connect fittings are dusty, clean with
an air blower, etc. and then remove it.
141RW016As some pressure may remain in the piping, cover the
connector with a cloth, etc. to prevent the splashing
of fuel in the first disconnection of the piping.

6G±7 ENGINE LUBRICATION
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
8. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
9. Remove pitman arm and relay lever assembly, using
the 5±8840±2005±0 remover, remove pitman arm
from the steering unit and remove four fixing bolts for
relay lever assembly.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack
and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5±8840±2153±0 sealer cutter,
remove oil pan.
013RS003
13. Remove crankcase fixing bolts.
14. Remove crankcase, using 5±8840±2153±0 sealer
cutter, remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or dam-
aged.
013RS003
Installation
1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.

The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.
013RW010

SERVICE INFORMATION 00 Ð 13
Checkpoint Possible cause Correction 4. SLAPPING NOISE
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Rocker arm Damaged rocker arm Replace the rocker arm
Flywheel Loose flywheel bolts Retighten the flywheel bolts
Crankshaft and
thrust bearingsWorn or damaged crankshaft and/or
thrust bearingsReplace the crankshaft and/or the
thrust bearings
Crankshaft and
connecting rod
bearingsWorn or damaged crankshaft and/or
connecting rod bearingsReplace the crankshaft and/or the
connecting rod bearings
Connecting rod
bushing and piston
pinWorn or damaged connecting rod bushing
and piston pinReplace the connecting rod bushing
and/or the piston pin
Piston and cylinder
linerWorn or damaged piston and cylinder liner.
Foreign material in the cylinder.Replace the piston and the cylinder
liner.

6A Ð 18 ENGINE MECHANICAL
8. Camshaft
1) Apply a coat of engine oil to the camshaft and the
camshaft bearings.
Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
7. Camshaft Thrust Plate
Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to specified torque.
6. Camshaft Timing Gear
1) Install the camshaft timing gear to the camshaft.
The timing gear mark ("Y - Y") must be facing out-
ward.
2) Tighten the timing gear to the specified torque.
5. Oil Pump Assembly
¥ Refer to Section 6A2 ÒOil Pump InstallationÓ.
4. Crankcase Assembly
¥ Refer to Section 6A2 ÒCrankcaseÓ.
3. Cylinder Block Rear Plate
¥ Tighten cylinder block rear plate fixing bolts to the
specified torque.
18 (1.8/13)N·m(Kg·m/lb·ft)
64 (6.5/47)N·m(Kg·m/lb·ft)
82 (8.4/61)N·m(kg·m/lb·ft)
2. Flywheel
¥ Refer to Section 6A2 ÒCrankshaft InstallationÓ.
1. Cylinder Head Assembly
¥ Refer to Section 6A2 ÒCylinder Head InstallationÓ.

6A Ð 32 ENGINE MECHANICAL
19 (1.9/14)N·m(kg·m/lb·ft)
5. Timing Gear Case
1) Install the timing gear case to the cylinder body.
NOTE:
Take care not to twist the front oil seal.
6. Flywheel
1) Thoroughly clean and remove the oil from the
threads of crankshaft.
2) Mount the flywheel on the crankshaft and then
install the washer.
3) Align the flywheel with the crankshaft dowel pin.
4) Tighten the flywheel bolts to the specified torque
in the numerical order shown in the illustration.
82 (8.4/61)N·m(kg·m/lb·ft)
NOTE:
Take care not to damage the O-rings when tightening the
oil pipe bolts.
9. Crankcase Assembly
·Refer to ÒCrankcaseÓ Section 6A2
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
7. Cylinder Block Rear Plate
Align the rear plate with the cylinder body knock pins.
Tighten the rear plate to the specified torque.
118 (12.0/87)N·m(kg·m/lb·ft)

6A Ð 50 ENGINE MECHANICAL
8. Camshaft Timing Gear
1) Install the camshaft timing gear to the camshaft.
The timing gear mark ("Y - Y") must be facing
outword.
2) Tighten the timing gear to the specified torque.
64 (6.5/47)N·m (kg·m/lb·ft)
7. Oil Pump Assembly
·Refer to ÔOil pumpÕ in Section 6A2.
6. Crankcase Assembly
·Refer to ÔCrankcaseÕ in Section 6A2.
5. 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
4. Cylinder Block Rear Plate
·Tighten the cylinder block rear plate fixing bolt to the
specified torque
82 (8.4/61)N·m (kg·m/lb·ft)
3. Flywheel
·Refer to ÔCrankshaftÕ in Section 6A.
2. Cylinder Head Gasket
1. Carefully remove carbon deposits and gasket
residue from the piston top face and the cylinder
body upper surface.