engine ISUZU TROOPER 1998 Service Repair Manual

6A2 Ð 4 4JG2-NA/4JG2-TURBO ENGINE
118 (12.0/87)N·m(kg·m/lb·ft)
ENGINE MOUNT (LH)
REMOVAL
Preparation:
·Disconnect battery ground cable
·Support engine
·Support vehicle
1. Front Tire
2. Dust Cover
3. Engine Mount
·Remove fixing bolts from cylinder body and
chassis frame.
INSTALLATION
3. Engine Mount
·Tighten the fixing bolts to the specified torque
2. Dust Cover
1. Front Tire
·Tighten the fire fixing nuts to specified torque
40 (4.1/30)
N·m(kg·m/lb·ft) Cylinder body side
40 (4.1/30)
N·m(kg·m/lb·ft) Chassis frame side
41 (4.2/30)
N·m(kg·m/lb·ft) Chassis frame side

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 5
INTERCOOLER (4JG2-T only)
REMOVAL
Preparation:
·Disconnect battery ground cable
1. Air Cleaner Cover & Air Duct
·Remove bolts from intercooler.
2. Vacuum Hose
3. Intercooler Assembly
·Disconnect outlet hose from intake manifold.
·Remove bolts from engine side brakets.
INSTALLATION
3. Intercooler
·Connect outlet hose to intake manifold.
·Install intercooler and tighten fixing bolts to the
specified torque.
19 (2.0/14)N·m (Kg·m/lb·ft)
2. Vacuum Hose
1. Air Cleaner Cover & Air Duct

6A2 Ð 6 4JG2-NA/4JG2-TURBO ENGINE
CYLINDER HEAD COVER
REMOVAL
Preparation:
·Disconnect battery ground cable.
1. Air Cleaner Cover & Air Duct (4JG2-T only)
·Disconnect two air hose.
·Release clips and bands and remove air cleaner
cover.
2. Intercooler Assembly (4JG2-Tonly)
·(Refer to intercooler removal steps in this section)
3. Heater and Oil Cooler Pipe Fixing Bolts
·Remove fixing bolts from.
4. Oil Level Gauge Tube
5. Cylinder head cover

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 7
INSTALLATION
5. Cylinder Head Cover
·Apply engine oil to the rocker arms and the valve
springs.
·Install the cylinder head cover gasket to the
cylinder head cover.
·The gasket must be perfectly smooth with no
loose areas.
·Tighten the cylinder head cover nuts to the
specified torque in the numerical order.
13 (1.3/113 lb·in)N·m(Kg·m/lb·in)
4. Oil Level Gauge Tube
19 (1.9/14)N·m(Kg·m/lb·ft)
Bolt
3. Heater and Oil Cooler Pipe Fixing Bolts
2. Intercooler Assembly (4JG2-T Only)
·(Refer to intercooler installation steps in this
section.)
1. Air Cleaner Cover & Air Duct

6A2 Ð 8 4JG2-NA/4JG2-TURBO ENGINE
INLET MANIFOLD
REMOVAL
1. Intercooler (4JG2-T only)
2. Oil Level Gauge Tube (4JG2-T only)
3. Heater and Oil Cooler Pipe Fixing Bolts.
·Remove fixing bolts from inlet manifold.
4. Injection Pipes
5. Inlet Manifold
INSTALLATION
5. Inlet Manifold
·Tighten the fixing bolts and nuts to the specified
19 (1.9/14)
N·m(Kg·m/lb·ft) Bolt
24(2.4/18)N·m(Kg·m/lb·ft)
Nut

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 9
4. Injection Pipes
·Tighten the sleeve nut to the specified torque
3. Heater and Oil Cooler Pipe Fixing Bolts
·Tighten fixing bolts to the specified torque
2. Oil Level Gauge Tube (4JG2-T only)
1. Inter Cooler (4JG2-T only)
·Refer to ÒInter cooler installationÓsteps in this
section.19 (1.9/14)N·m(Kg·m/lb·ft)
29 (3.0/22)N·m(Kg·m/lb·ft)

6A2 Ð 10 4JG2-NA/4JG2-TURBO ENGINE
EXHAUST MANIFOLD
REMOVAL
1. Turbocharger (4JG2-T only)
·Refer to the ÒTurbochargerÓ removal in this
section.
2. Exhaust Manifold
INSTALLATION
2. Exhaust Manifold
·Tighten the fixing nuts and bolts to the specified
torque.
1. Turbocharger (4JG2-T only)
·Refer to the ÒTurbochargerÓ installation in this
section.
26 (2.7/20)
N·m(Kg·m/lb·ft)
Bolt
19 (1.9/14)
N·m(Kg·m/lb·ft)
Nut

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

6A2Ð 12 4JG2-NA/4JG2-TURBO ENGINE
5. Air Conditioner (A/C) Compressor Assembly
·Remove A/C compressor fixng bolt (rear under
side of compressor) by using a long extension bar
at under side of wheel arch.
·Disconnect magnetic clutch harness connector.
·Removal fixing bolts (upper and front lower sides
of compressor) and set A/C compressor asm with
pipelines on battery cable.
6. Water Inlet Pipe: Turbo (4JG2-T Only)
7. Oil Feed Pipe: Turbo (4JG2-T Only)
·Remove joint bolt from turbo charger.
·Plug up oil port of turbocharger to prevent
entrance of foreign material.
8. Oil Return Pipe: Turbo (4JG2-T Only)
·Disconnect oil return pipe flange from
turbocharger.
9. Water Outlet Pipe: Turbo (4JG2-T Only)
10. Exh. Pipe: Ft (4JG2-T Only)
11. Heat Protector (4JG2-T Only)
12. Exh. Adapter (4JG2-T Only)
13. Turbocharger Assembly (4JG2-T Only)
·Remove turbocharger asm from exhaust
manifold.

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 13
26 (2.7/20)N·m(Kg·m/lb·ft)
INSTALLATION
13. Turbocharger Assembly (4JG2-T Only)
·Install the turbocharger asm with gasket in exh.
manifold and tighten fixing nuts to the specified
torque.
12. Exh. Adapter (4JG2-T Only)
·Install exh. adapter and tighten bolts to the
specified torque.
11. Heat Protector (4JG2-T Only)
10. Exh. Pipe: Ft
·Install exh. pipe and tighten bolts to the specified
torque.
9. Water Outlet Pipe: Turbo (4JG2-T Only)
·Install water outlet pipe with new gasket to the
specified torque.
26 (2.7/20)N·m(Kg·m/lb·ft)
67 (6.8/49)N·m(Kg·m/lb·ft)
8(0.8/6)N·m(Kg·m/lb·ft)