check engine ISUZU TROOPER 1998 Service Manual PDF

6A±60
ENGINE MECHANICAL
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
014RS014
Valve Seat Insert Replacement
1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
3. Strike the rod and pull it out.
014RS015
4. Carefully clean the valve seat press±fit section on the
cylinder head side.
5. Heat the press±fit section with steam or some other
means to cause expansion. Cool the valve seat with
dry ice or some other means.
6. Insert the press±fit section into the valve seat
horizontally.
Standard fitting interference: 0.14 mm±0.09 mm
(0.0055 in±0.0035 in)7. After insertion, use a seat grinder to grind finish the
seating face. Carefully note the seating angle, the
contact width, and the depression.
8. Lap the valve and the seat.
Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer 5±8840±2442±0, drive in a new valve guide
from the camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5±8840±0623±0, drive in
a new oil controller.
014RW058
3. Install valve to valve guide. Before install valve guide
apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve
spring to the lower spring seat. The painted area of
the valve spring should be facing downward.
014RS020

6A±61
ENGINE MECHANICAL
5. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using the 5±8840±2446±0 valve spring
compressor and 5±8840±2547±0 valve spring
compressor adapter to install the split collars.
014RW042
6. Install tappet with shim.
7. Install camshaft assembly.

Refer to installation procedure for Camshaft in this
manual.
Valve Clearance Adjustments
NOTE: To adjust valve clearance, apply engine oil to the
cam as well as to the adjusting shim (2) with the cylinder
head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite to maximum cam lift (1) as shown in illistration
below.
014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)
Intake: 0.23 mm±0.33 mm
(0.0091 in±0.0130 in)
Exhaust: 0.25 mm±0.35 mm
(0.0098 in±0.0138 in)
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement ± Standard valve)
Based on the above formula, the best suited shim should
be selected from 41 sorts of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.

6A±70
ENGINE MECHANICAL
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to ªPiston, Piston Ring and Connecting Rodº in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair
1. Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm±0.24 mm
(0.0024 in±0.0094 in)
Limit : 0.30 mm (0.0118 in)
015RS003
Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
015RS004
3. Remove the crankshaft.
Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.
015RS005
9. Install main bearing caps, oil gallery and crank case
bolts in the order shown, and tighten each bolt to the
specified torque.

6A±75
ENGINE MECHANICAL
4. Piston and connecting rod assembly (8)

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
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 must be facing the front of the engine.

Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.

Apply engine oil to the threads and seating faces of
the nuts.

Tighten the nuts.
Torque: 54 N´m (5.5 Kg´m/40 lb ft)
After tightening the cap nuts, check to see that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces.
015RS020
5. Install oil gallery (7) 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

051RS009
6. Cylinder block side bolts (6)

Tighten all the bolts to the specified torque in the
order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 N´m (4.0 Kg´m/29 lb ft)

6A±78
ENGINE MECHANICAL
015RS031

Remove any ridge or carbon build up from the top
end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.
015RS022
10. Remove the piston pin (9) using 5±8840±0551±0
piston pin service set and piston support with a press.
NOTE: Keep the parts removed from each cylinder
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons (10)
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must be
replaced.
Piston Diameter
1. Measure the piston outside diameter with micrometer
at the piston grading position and a right angle to the
piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)

6A±81
ENGINE MECHANICAL
Connecting Rods (11)
1. Check the connecting rod alignment If either the bend
or the twist exceeds the specified limit, the connecting
rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)
015RS030
2. Measure the connecting rod thrust clearance. Use a
feeler gauge to measure the thrust clearance at the
large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod must
be replaced.
Standard : 0.16 mm±0.35 mm
(0.0063 in.±0.0138 in)
Limit : 0.40 mm (0.0157 in)
015RS031
3. Measure the oil clearance between the connecting
rod and the crankshaft.
1. Remove the connecting rod cap nuts and the rod
caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn, the
entire bearing assembly must be replaced as a
set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.
015RS032

6A±83
ENGINE MECHANICAL

Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.
015RS036

With 5±8840±0551±0 Piston pin service set and a
press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
4. Install piston ring with the piston ring expander.
The compression ring must be set with the T mark (1)
facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
015RS027

Install piston rings in the following sequence.
1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
3. 1st compression ring

The compression rings must be set with the T or T2
mark facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring

After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.
015RS038
5. Install piston and connecting rod assembly.

Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.

6A±86
ENGINE MECHANICAL
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the cylinder
block. Be very careful not to allow any material to
accidentally drop into the cylinder block. Be very
careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal retainer,
and crankcase assembly installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary, use a
flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must either
be repaired or replaced.
Flatness
1. Using a straight±edge and feeler gauge, check that
the upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 (3.6823)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm±93.410 mm
(3.6772 in±3.6776 in)
Grade B : 93.411 mm±93.420 mm
(3.6776 in±3.6779 in)
Grade C : 93.421 mm±93.430 mm
(3.6780 in±3.6783 in)
012RS005
NOTE: For information on piston diameter, please refer
to the section ºInspection of the Piston and Connecting
Rod Assemblyº in this manual.

The ºGradeº mark (1) is stamped at the position
illustrated.

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

6B±4
ENGINE COOLING
NOTE: An t if r e e ze s o lu t io n + Water = Total cooling
system capacity.

Total Cooling System Capacity

M/T 8.8Lit (2.32Us gal)

A/T 8.4Lit (2.22Us gal)
B06RW002

Mixing ratio
Check the specific gravity of engine coolant in the
cooling system temperature ranges from 0
C to 50
C
using a suction type hydrometer, then determine the
density of the engine coolant by referring to the table.
NOTE:
1. Even in the areas where the atmospheric
temperature is higher than 0
C, be sure not to use
antifreeze solution at a mixing ratio lower than 20% so
that the inside of the engine may not be corroded.
2. If antifreeze solution is used at a mixing ratio higher
than 60%, the specific heat of the coolant falls and the
engine may be overheated. Moreover, antifreeze
performance drop and the coolant may be frozen.
The density of the solution must be adjusted as
occasion calls.
Antifreeze solution lower than 20% may not have
sufficient anticorrosive performance, and therefore,
please never fail to adjust as occasion demands within
the range of 20% to 60%.
B06RW003