radiator ISUZU TROOPER 1998 Service Manual PDF

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 16 FUEL SYSTEM
20 (2.0/15)N·m (Kg·m/lb·ft)
·Tighten the injection pump bracket bolts 8 to the
specified torque..
40 (4.1/30)N·m (Kg·m/lb·ft)
12. Injection Pipe
·Connect the pump side and nozzle side of the pipe,
and tighten securely.
·Install clip where it was.
11. Injection Pump Control Cable
·See adjustment of accelerator control cable.
10. Fuel Hose & CSD Hose
9. Injection Pump Harness
·Mount engine harness and connect it to switches.
8. Fuel Filter Assembly
7. Timing Gear
·Refer to Timing Gear in Section 6A2.
6. AC Generator Drive Belt
·Mount AC Generator drive belt and adjust belt
tension.
·See drive belt adjustment in section 6B.
5. P/S Pump Drive Belt
·Mount P/S pump drive belt and adjust belt tension.
·See drive belt adjustment in section 6B.
4. Cooling Fan Assembly
·Mount fan pulley, distance piece, and cooling fan
asm (in this order) on the water pump, and tighten
to the specified torque.
3. Radiator Assembly
2. Intercooler Assembly (4JG2-T ONLY)
·See installation of intercooler.
·Pour coolant.
·Connect battery ground cable.
1. Air Cleaner Cover & Air Duct
INSTALLATION
13. Injection Pump Assembly
·Tighten the injection pump bracket bolts 7 to the
specified torque..
8 (0.8/69)N·m (Kg·m/lb·in)

6A – 4 ENGINE MECHANICAL
Engine Cooling
Starting System
Cooling system Coolant forced circulation
Radiator (2 tube in row) Tube type corrugated
Heat radiation capacity J/h (kcal/h) 318 x 10
6(76000)
Heat radiation area m
2(ft2) 15.63 (1.454)
Front area m
2(ft2) 0.309 (2.029)
Dry weight N (kg/lb) 83 (8.5/18.7)
Radiator cap
Valve opening pressure kPa (kg/cm
2/ psi) 93.3 – 122.7 (0.95 – 1.25/13.5 – 17.8)
Coolant capacity lit (Imp.qt./US qt.) M/T 2.5 (2.2/2.6) A/T 2.4 (2.1/2.5)
Coolant pump Centrifugal impeller type
Pulley ratio (to 1) 1.2
Coolant total capacity lit (Imp.qt./US qt.) 9.3 (8.2/9.8)
Model HITACHI S14-0
Rating
Voltage V 12
Output kW 2.8
Time sec 30
Number of teeth of pinion 9
Rotating direction (as viewed from pinion) Clockwise
Weight (approx.) N(kg/lb) 49 (5.0/11)
No-load characteristics
Voltage/current V/A 11/160 or less
Speed rpm 4000 or more
Load characteristics
Voltage/current V/A 8.76/300
Torque N·m(kg·m/lb·ft) 7.4 (0.75/5.4) or more
Speed rpm 1700 or more
Locking characteristics
Voltage/current V/A 2.5/1100 or less
Torque N·m(kg·m/lb·ft) 18.6 (1.9/14) or more

6A – 8 ENGINE MECHANICAL
Parts Items Service standard Service limit Remarks
Cylinder
Block—
95.421 – 95.450
(3.7567 – 3.7579)0.20 (0.0079) Warpage
(Upper surface of the cylinder block)
Cylinder bore diameter
Parts Items Service standard Service limit Remarks
Thermostat
Radiator cap83 – 87°C
(181 – 189°F)
More than 9.5 (0.374)
at 100°C (212°F)
88.2 – 117.6 kPa
(12.8 –17.0 psi) Valve opening temperature
Valve full open temperature and lift
Valve opening pressure
Engine Coolingmm (in) mm (in)

6A – 10 ENGINE MECHANICAL
8. Check the engine oil level and replenish to the
specified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel filter
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
Filter Wrench : 5-8840-0203-0
2. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn the fuel filter with a filter wrench 2/3 of a turn
until sealed.
Filter Wrench: 5-8840-0203-0Legend
(1) Priming pump
6. Operate the priming pump until the air is discharged
completely from fuel system.
NOTE: The use of an Isuzu genuine fuel filter is
strongly recommended.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator
reserve tank as necessary.
If the coolant level falls below the “‘MIN” line, carefully
check the cooling system for leakage. Then add
enough coolant to bring the level up to the “MAX” line.
NOTE: Do not overfill the reserve tank.
012RW112
012RW078
1
012RW111
012RW080

ENGINE MECHANICAL 6A – 11
Remove the radiator filler cap only when absolutely
necessary.
Always check the coolant level when the engine is cold.
Always refer to the chart at the left to determine the
correct cooling water to antifreeze solution mixing ratio.
Cooling System Inspection
Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage.
The testing pressure must not exceed the specified
pressure.
Testing Pressure: 196 kPa (2 kg/cm
2/28.45 psi)
Radiator Cap Inspection
The radiator filler cap is designed to maintain coolant
pressure in the cooling system at 103 kPa (1.05
kg/cm
2/15 psi).
Check the radiator filler cap with a radiator filler cap
tester.The radiator filler cap must be replaced if it fails to hold
the specified pressure during the test procedure.
Radiator Filler Cap Pressure Valve: 88.2 – 117.6 kPa
(0.899 – 1.199 kg/cm
2/12.8 – 17.1 psi)
Negative Valve (Reference): 1.0 – 3.9 kPa
(0.01 – 0.04 kg/cm
2/0.14 – 0.57 psi)
Thermostat Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature:
83 – 87°C (181 – 189°F)
4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature:
100°C (212°F)
Valve Lift at Fully Open Position: 9.5 mm (0.374
in)0
-10
-20
-30
-40
-50
-60
10 20 30
Mixing ratio (%)
Freezing point ( °C)
40 50 60
111RW002
110RS005
110RS006
031RS003

6A – 28 ENGINE MECHANICAL
ENGINE ASSEMBLY
For General Export
For Europe
F06R200004
REMOVAL
1. Remove battery.
2. Drain engine coolant
3. Disconnect window washer hose and remove
engine hood.
4. Radiator Hose
1) Disconnect upper and lower hoses from engine
side.
5. Fan Shroud
1) Disengage clips and remove upper and lower
fan shrouds.
6. Cooling Fan Assembly
1) Remove cooling fan assembly fixing nuts,
cooling fan assembly.
7. Radiator Assembly1) Remove bracket and radiator assembly.
8. Air Cleaner Cover & Air Duct
9. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
10. Engine Ground Cable
1) Disconnect ground cable from A/C compressor
bracket.
11. AC Generator Harness
1) Disconnect B terminal and harness connector
from AC generator.
12. A/C Compressor Assembly
1) Disconnect magnetic clutch harness connector.
2) Remove A/C compressor fixing bolt (rear under
side of compressor).
3) Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor
assembly with pipe lines on battery carrier.

ENGINE MECHANICAL 6A – 29
13 Vacuum Hose
1) Disconnect vacuum hose from vacuum pump.
14. Starter Harness
1) Disconnect B terminal and put cable harness
close to chassis side.
2) Disconnect S terminal connector.
15. Engine Harness
1) Disconnect engine harness close to engine side.
16. Fuel Pipe
1) Remove fuel pipe from fuel pump and take care
not to spill fuel and let dust enter.
17. Engine Ground Cable
1) Disconnect ground cable from left rear side of
timing gear case.
18. Vacuum Hose: Vacuum Tank
Disconnect vacuum hose from vacuum pump side.
19. Glow Plug Harness
20. Transmission Assembly
1) Set transmission support tool under the
transmission.
2) Remove transmission rear mount.
3) Remove transmission fixing bolt from rear of
engine assembly except two bolts.
4) Carefully hang up engine assembly with a hoist.
5) Remove remaining two transmission fixing bolts.
6) Remove transmission assembly.
7) Remove heater hose.
8) Disconnect wire harness connector for shift on
the fly.
9) Remove vacuum hose.
21. Prepare Engine Stand
22. Engine Assembly
1) Remove engine mount fixing bolts.
2) Carefully hang up the engine assembly.
3) Take out the engine assembly making sure not
to damage the brake oil pipe and other pipe etc.
INSTALLATION
1. Engine assembly
1) Install engine in mounting position by using
hoist.
2. Transmission Assembly
1) Refer to transmission installation steps in
section 7.
3. Engine Mounting
1) After all fixing bolts (left: two bolts, rights: two
bolts) were inserted in every hole, tighten fixing
bolts to the specified torque.
Torque: 40 N·m (4 kg·m/29 lb·ft)
4. Glow Plug Harness
5. Vacuum Hose
1) Connect Vacuum Hose to Vacuum Pump
6. Engine Ground Cable
7. Fuel Pipe
1) Install fuel pipe to fuel pump.
8. Engine Harness
9. Starter Harness
10. A/C Compressor Assembly
1) Tighten temporarily the fixing bolts (upper and
front lower sides of compressor.)2) Tighten fixing bolt (rear under side of
compressor) to the specified torque.
3) Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.
Torque: 40 N·m (4 kg·m/29 lb·ft)
Legend
(1) Tensioner
(2) Bolt
(3) Bracket
(4) A/C compressor
(5) Bolt
11. A.C Generator Harness
12. Engine Ground Cable
1) Tighten ground cable to A/C compressor
bracket.
13. Air Cleaner cover & Duct
14. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
15. Radiator Assembly
1) Install rubber cushion in under left and right part
of radiator and position radiator.
2) Fix radiator with bracket.
16. Cooling Fan Assembly
1) Install cooling fan assembly and tighten fixing
bolts to the specified torque.
Torque: 8 N·m (0.8 kg·m/5.8 lb ft)
17. Fan Shroud
18. Radiator Hose
1) Connect upper and lower hose to engine side.
2) Pour coolant into radiator.
19. Install battery.
20. Connect window washer hose and install engine
hood.
1
2
3
4
5
'PS
&VSPQF
F06R200005

6A – 44 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove air cleaner and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Remove PCV hose.
7. Remove EGR vacuum hose.
8. Disconnect harness connector around the cylinder
head.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out fan belt.
12. Remove heat protector and remove valve
assembly.
13. Remove water hose and oil pipe from turbocharger.
14. Remove turbocharger assembly.
15. Remove water hose between thermostat and
radiator.
16. Remove cylinder head noise insulator cover.
NOTE: Do not make damage to the harness.
17. Remove high pressure pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner and remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove water pipe between cylinder head and
water pump.
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe.
26. Remove intake manifold assembly.
27. Disconnect glow plug wiring and remove glow plug.
28. Remove cylinder head cover.
29. Drain oil from oil rail.
30. Disconnect injector harness connector.
31. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
32. Disconnect injector harness assembly.
33. Remove injector clamp.
34. Remove injector spacer (If equipped.).
35. Remove injector assembly.
36. Remove oil rail assembly.
37. Remove camshaft carrier.
38. Remove cylinder head assembly.
39. Remove cylinder gasket.
INSTALLATION
1. Install cylinder head gasket with top mark up.
NOTE: Determine cylinder head gasket grade by
measuring projection of piston head.2. Selection cylinder head gasket.
1) Measure the piston head projection by dial
gauge.
2) Measure the projection of piston head at the
nearest possible point to the cylinder bore.
3) Obtain the largest measurement from among all
cylinders.
4) Determine cylinder head gasket grade by
maximum value of measuring projection of
piston head.
Legend
(1) Top Mark
(2) Grade Mark
012RW073
2 1
011RW043

6A – 46 ENGINE MECHANICAL
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt, Stud and Rubber Mounting
21. Install water hose between thermostat and radiator.
22. Install turbocharger assembly to exhaust manifold.
Torque: 27 N·m (2.8 kg·m/20.2 lb ft)
23. Install water hose and oil pipe for turbocharger.
24. Install exhaust valve assembly and heat protector.
Torque: 27 N·m (2.8 kg·m/20.2 lb ft) for valve
Torque: 9 N·m (0.9 kg·m/6.5 lb ft) for heat protector25. Install generator assembly.
Torque: 40 N·m (4.0 kg·m/29 lb ft) for ACG bracket
Torque: 40 N·m (4.0 kg·m/29 lb ft) between ACG and
bracket
Torque: 20 N·m (2.0 kg·m/14.5 lb ft) between ACG
and adjuster plate
26. Fix the A/C compressor bracket and install A/C
compressor.
Torque: 47 N·m (4.7 kg·m/34 lb ft) for A/C bracket
Torque: 20 N·m (2.0 kg·m/14.5 lb ft) for belt tensioner
27. Reconnect harness connector around cylinder
head.
28. Connect EGR vacuum hose.
29. Install oil level gauge guide assembly.
Tighten nuts lower portion and tighten bolt.
Torque: 20 N·m (2.0 kg·m/14.5 lb ft)
30. Install intercooler assembly.
Refer to “Intercooler” in this manual.
31. Install air duct between air cleaner and
turbocharger.
32. Fill engine coolant.
33. Reconnect battery.
For Europe
025R200007
For Europe
025R200006
1 7
2
3
4
5 6
010R200006