Remove engine ISUZU TROOPER 1998 Service Workshop Manual

6A±5
ENGINE MECHANICAL
4. Engine Lacks Compression
Condition
Possible causeCorrection
Engine lacks compressionSpark plug loosely fitted or spark
plug gasket defectiveTighten to specified torque or replace
gasket
Valve timing incorrectAdjust
Cylinder head gasket defectiveReplace gasket
Valve incorrectly seatedLap valve
Valve stem seizedReplace valve and valve guide
Valve spring weakened or brokenReplace
Cylinder or piston rings wornOverhaul engine
Piston ring seizedOverhaul engine.
Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

6A±11
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine overheatingLevel of Engine Coolant too lowReplenish
Fan clutch defectiveReplace
Incorrect fan installedReplace
Thermostat defectiveReplace
Engine Coolant pump defectiveCorrect or replace
Radiator cloggedClean or replace
Radiator filler cap defectiveReplace
Level of oil in engine crankcase too
low or wrong engine oilChange or replenish
Resistance in exhaust system
increasedClean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrectReplace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shortedCorrect or replace
Cylinder head gasket damagedReplace
Engine overcoolingThermostat defectiveReplace (Use a thermostat set to
open at 82
C (180
F))
Engine lacks compressionÐÐÐÐRefer to Hard Start
OthersTire inflation pressure abnormalAdjust to recommended pressures
Brake dragAdjust
Clutch slippingAdjust or replace
Level of oil in engine crankcase too
highCorrect level of engine oil
Exhaust Gas Recirculation Valve
defectiveReplace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and othermoving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Condition
Possible causeCorrection
Noise from crank journals or from
crank bearings
(Faulty crank journals and crankOil clearance increased due to worn
crank journals or crank bearingsReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
yj
bearings usually make dull noise that
becomes more evident when
accelerating)Crankshaft out of roundReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seizedCrank bearing seized. Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defectivebearing by listening for abnormal noise that stops when
spark plug is shorted out.

6A±14
ENGINE MECHANICAL
Condition CorrectionPossible cause
Trouble in emission control systemHeated Oxygen Sensor circuit openCorrect or replace
Heated Oxygen Sensor defectiveReplace
Signal vacuum hose loosely fitted or
defectiveCorrect or replace
EGR Valve circuit open or shortedCorrect or replace
Exhaust Gas Recirculation Valve
defectiveReplace
ECT Sensor circuit open or shortedCorrect or replace
Canister Purge Valve circuit open or
shortedCorrect or replace
Canister Purge Valve defectiveReplace
ECT Sensor defectiveReplace
Positive Crankcase Ventilation
(PCV) valve and hose cloggedCorrect or replace
Evaporator systemRefer to Section 6E
Trouble in ignition systemÐÐÐÐRefer to ªEngine Lacks Powerº
Trouble in cylinder head partsCarbon deposits in combustion
chamberRemove carbon
Carbon deposit on valve, valve seat
and valve guideRemove carbon
Engine Oil Consumption Excessive
ConditionPossible causeCorrection
Oil leakingOil pan drain plug looseRetighten or replace gasket
Crankcase fixing bolts loosenedRetighten
Oil pan setting bolts loosenedRetighten
Oil pan gasket brokenReplace gasket
Front cover retaining bolts loose or
gasket brokenRetighten or replace gasket
Head cover fixing bolts loose or
gasket brokenRetighten or replace gasket
Oil cooler adapter crackedReplace
Oil cooler center bolt looseRetighten
Oil cooler O±ring brokenReplace
Oil cooler piping loose or brokenRetighten or replace
Oil filter adapter crackedReplace
Oil filter attaching bolt loose or rubber
gasket brokenRetighten or replace oil filter
Oil cooler brokenReplace
Crankshaft front or rear oil seal
defectiveReplace oil seal
Oil pressure unit loose or brokenRetighten or replace
Blow±by gas hose brokenReplace hose
Positive Crankcase Ventilation Valve
cloggedClean
Engine/Transmission coupling failedReplace oil seal

6A±16
ENGINE MECHANICAL
Lubrication Problems
ConditionPossible causeCorrection
Oil pressure too lowWrong oil in useReplace with correct engine oil
Relief valve stickingReplace
Oil pump not operating properlyCorrect or replace
Oil pump strainer cloggedClean or replace strainer
Oil pump wornReplace
Oil pressure gauge defectiveCorrect or replace
Crankshaft bearing or connecting
rod bearing wornReplace
Oil contaminationWrong oil in useReplace with correct engine oil
Oil filter cloggedReplace oil filter
Cylinder head gasket damageReplace gasket
Burned gases leakingReplace piston and piston rings or
cylinder body assembly
Oil not reaching valve systemOil passage in cylinder head or
cylinder body cloggedClean or correct
Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine oil.
a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the ªMaintenance and Lubricationº section
of this manual.
2. Check the engine oil level.
The level should fall somewhere between the ªADDº
and the ªFULLº marks on the oil level dipstick.
If the oil level does not reach the ªADDº mark on the
oil level dipstick, engine oil must be added.3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal
operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
392±550 kPa (56.9±80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

6A±18
ENGINE MECHANICAL
Cylinder Head Cover LH
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from faucet bottom of radiator.
3. Remove engine cover from the dowels on the
common chamber.
F06RW018
4. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.5. Disconnect following wiring connectors and bonding
cable:

Manifold Absolute Pressure (MAP) sensor

Vacuum Switching Valve (VSV) for Induction Air
Control Valve (IACV) actuator

Ignition coils for left bank

Fuel injectors for left bank

Idle air control (IAC) valve

Throttle position sensor (TPS)

Bonding cable

Others as necessitated
6. Disconnect following vacuum hoses:

Brake master VAC

Canister

VSV for IACV actuator

Duty solenoid valve

PCV
7. Disconnect radiator upper and lower hoses
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019

6A±19
ENGINE MECHANICAL
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove power steering oil pump pulley.
13. Remove fan pulley and bracket assembly.
14. Remove idle pulley assembly.
15. Remove auto tensioner assembly.
16. Remove crankshaft pulley using 5±8840±0133±0
crankshaft holder.
17. Remove timing belt covers from the right bank side to
the left bank side in order.
18. Remove ignition coil assemblies for the left side bank.
060RW018
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
19. Remove cylinder head cover assembly.
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bracket on front and rear sides.
The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
014RW144

Tighten bolts to the specified torque.
Torque : 9 N´m (0.9 Kg´m/78 lb in)
010RW008
2. Install ignition coil assemblies and tighten the fixing
bolts to the specified torque.
Torque : 4 N´m (0.4 Kg´m/35 lb in)
3. Install timing belt covers from left bank side to right
bank side, and tighten the fixing bolts and nut to the
specified torque.
Torque : 19 N´m (1.9 Kg´m/14 lb ft)
4. Install crankshaft pulley and tighten the fixing bolt
using 5±8840±0133±0 crankshaft holder to the
specified torque.
Torque : 167 N´m (17.0 Kg´m/123 lb ft)

6A±21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:

Exhaust Gas Recirculation (EGR) valve

Fuel injectors for right bank

Ignition coils for right bank

Bonding cable

Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5±8840±0133±0
crankshaft holder.

6A±22
ENGINE MECHANICAL
16. Remove timing belt covers for right bank side.
17. Reomve timing belt covers for right bank side.
060RW001
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
18. Remove ignition coil assemblies for the right side
bank.
19. Remove cylinder head cover assembly.
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bracket on front and rear sides.

The cylinder head cover must be installed within 5
minutes after sealant application before the sealant
hardens.
014RW143

Tighten bolts in turn to the specified torque.
Torque : 8.8 N´m (0.9 Kg´m/78 lb in)
010RW007
2. Install ignition coil assemblies and tighten the fixing
bolts to the specified torque.
Torque : 4 N´m (0.4 Kg´m/35 lb in)
3. Install timing belt cover and tighten the fixing bolts and
nut to the specified torque.
Torque : 19 N´m (1.9 Kg´m/14 lb ft)
4. Install crankshaft pulley and tighten the fixing bolt
using 5±8840±0133±0 crankshaft holder to the
specified torque.
Torque : 167 N´m (17 Kg´m/123 lb ft)
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 N´m (2.0 Kg´m/14.8 lb ft)
Longer Bolt : 39 N´m (4.0 Kg´m/28.8 lb ft)

6A±24
ENGINE MECHANICAL
Common Chamber
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Air Flow Sensor
3. Disconnect accelerator pedal cable from throttle body
and cable bracket.
4. Disconnect vacuum booster hose from common
chamber.
5. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.
6. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
7. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
8. Remove the four throttle body fixing bolts.
9. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber and remove
EGR valve assembly.
10. Remove two bolts from common chamber rear side
for remove fuel hose bracket.
11. Remove common chamber four bolts and four nuts
then remove the common chamber.
025RW001
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt
Installation
1. Install common chamber and tighten bolts and nuts to
the specified torque.
Torque :
Bolt : 25 N´m (2.5 Kg´m/18 lb ft)
Nut : 25 N´m (2.5 Kg´m/18 lb ft)
2. Install fuel hose bracket and tighten bolts to specified
torque.
Torque : 10 N´m (1.0 Kg´m/89 lb in)
3. Install exhaust gas recirculation valve assembly and
tighten bolt and nut to the specified torque.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
4. Install throttle body and tighten bolts to the specified
torque.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
5. Install ventilating hose to throttle valve and intake
duct.
6. Connect vacuum hoses on canister VSV and positive
crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
7. Connect each connector without fail.
8. Connect vacuum booster hose.
9. Connect accelerator pedal cable.
Accelerator pedal cable adjustment
1. Loosen the adjusting nut and screw cap.
2. Pull outer cable while fully closing the throttle
valve.

6A±26
ENGINE MECHANICAL
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
3. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end of exhaust
front pipe.
150RW062
Legend
(1) Exhaust Front Pipe LH
4. Remove heat protector two fixing bolts then the heat
protector.5. Remove a bolt on engine LH side for air conditioner
(A/C) compressor bracket and loosen two bolts for
A/C compressor then move A/C compressor to front
side.
6. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
Torque: 57 N´m (5.8 Kg´m/42 lb ft)
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque :
Stud nuts: 67 N´m (6.8 Kg´m/49 lb ft)
Nuts: 43 N´m (4.4 Kg´m/32 lb ft)
150RW062
Legend
(1) Exhaust Front Pipe LH
4. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.
Torque : 40 N´m (4.1 Kg´m/30 lb ft)
5. Install air cleaner duct assembly.