Turbo ISUZU TROOPER 1998 Service Repair Manual

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4JG2
4JX1 SECTION No. CONTRNTS
00 SERVICE INFORMATION
6A ENGINE MECHANICAL
6A2 4JG2-NA / 4JG2-TURBO ENGINE
6B ENGINE COOLING
6C FUEL SYSTEM
6D ENGINE ELECTRICAL
6E -
6F EXHAUST
6G -
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL
6J INDUCTION

SAE Ð Society of Automotive Engineers
Sec Ð Secondary
SFI Ð Sequential-port Fuel Injection
SI Ð System International
SIR Ð Supplemental Inflatable Restraint System
SOHC Ð Single Overhead Camshaft
Sol Ð Solenoid
SPEC Ð Specification
Speedo Ð Speedometer
SRS Ð Supplemental Restraint System
ST Ð Start
Sw Ð Switch
SWB Ð Short Wheel Base
SYN Ð Synchronize
TAC Ð Thermostatic Air Cleaner
Tach Ð Tachometer
TBI Ð Throttle Body Injection
TCC Ð Transmission/Transaxle Converter Clutch
TCM Ð Transmission/Transaxle Control Module
TDC Ð Top Dead Center
Term Ð Terminal
TEMP Ð Temperature
TPS Ð Throttle Position Sensor
TRANS Ð Transmission/Transaxle
TURBO Ð Turbocharger
TV Ð Throttle Valve
TVRS Ð Television & Radio Suppression
TVS Ð Thermal Vacuum Switch
3 A/T Ð Three Speed Automatic Transmission/
Transaxle
2WD Ð Two Wheel Drive
4x2 Ð Two wheel Drive
U-joint Ð Universal Joint
V Ð Volt(s)
VAC Ð Vacuum
VIN Ð Vehicle Identification Number
VRRRE Ð Vehicle Refrigerant Recovery and Recycling
Equipment
V-ref Ð ECM Reference Voltage
VRV Ð Vacuum Reducer Valve
VSS Ð Vehicle Speed Sensor
VSV Ð Vacuum Switching Valve
V-6 Ð Six Cylinder ÒVÓ Engine
V-8 Ð Eight Cylinder ÒVÓ Engine
W Ð Watt(s)
w/ Ð With
w/b Ð Wheel Base
w/o Ð Without
WOT Ð Wide Open ThrottleL Ð Liter
lbáft Ð Foot Pounds
lbáin Ð Inch Pounds
LF Ð Left Front
LH Ð Left Hand
LR Ð Left Rear
LS Ð Left Side
LWB Ð Long Wheel Base
L-4 Ð In-line Four Cylinder Engine
MAF Ð Mass Air Flow
MAN Ð Manual
MAP Ð Manifold Absolute Pressure
MAT Ð Manifold Air Temperature
MEM-CAL Ð Memory and Calibration Unit
Max Ð Maximum
M/C Ð Mixture Control
Min Ð Minimum
mm Ð Millimeter
MPFI Ð Multi-Port Fuel Injection
MPG Ð Miles per Gallon
MPH Ð Miles per Hour
M/T Ð Manual Transmission/Transaxle
MV Ð Millivolt
NA Ð Natural Aspirated
NC Ð Normally Closed
Nám Ð Newton Meters
NO Ð Normally Open
NOx Ð Nitrogen, Oxides of
OD Ð Outside Diameter
O/D Ð Over Drive
OHC Ð Overhead Camshaft
OL Ð Open Loop
O
2Ð Oxygen
PAIR Ð Pulse Air Injection Reactor System
P/B Ð Power Brakes
PCV Ð Positive Crankcase Ventilation
PFI Ð Port Fuel Injection
PRESS Ð Pressure
PROM Ð Programmable Read Only Memory
P/N Ð Park/Neutral
P/S Ð Power Steering
PSI Ð Pounds per Square Inch
Pt. Ð Pint
Pri Ð Primary
PWM Ð Pulse Width Modulated
Qt Ð Quart
REF Ð Reference
RF Ð Right Front
RFI Ð Radio Frequency Interference
RH Ð Right Hand
RPM Ð Revolutions per Minute
RPO Ð Regular Production Option
RR Ð Right Rear
RS Ð Right Side
RTV Ð Room Temperature Vulcanizing
RVB Ð Rear Vacuum Brake
RVR Ð Response Vacuum Reducer
RWAL Ð Rear Wheel Antilock Brake
RWD - Rear Wheel Drive
GENERAL INFORMATION 0AÐ13

1B Ð 28 AIR CONDITIONING
REMOVAL
Preparation:
·Battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section)
1. Air Duct (Turbo to air cleaner)
Cover up the air duct connecting portion to prevent
foreign materials from getting into the turbo and the
air cleaner.
2. Magnetic Clutch Harness Connector
3. Drive Belt
Loosen the power steering pump unit fixing bolts,
then loosen the drive belt adjustment bolt and
remove the drive belt.
4. Refrigerant Line Connector
5. Compressor
Drive belt
Power steering
pump Tension
adjustment bolt
INSTALLATION
5. Compressor
Tighten the compressor fixing bolts to the specified
torque.
Compressor Bolt Torque Nám (kgám / lbáft)
40 (4.1 / 30)
4. Refrigerant Line Connector
·O-rings cannot be reused. Always replace with new
ones.
·Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
·Tighten the refrigerant line connector to the
specified torque.
Refrigerant Line Bolt Torque Nám (kgám / lbáft)
27 (2.8 / 20)

AIR CONDITIONING 1B Ð 29
3. Drive Belt
1) Temporary tighten the power steering pump unit
fixing bolts.
2) Push the drive belt when the force of 98N {10kgf}.,
and adjust the drive belt tension by tightening
drive belt tension adjustment bolt, till the 14 ~17
mm (0.55 ~0.67 in) of deflection of the belt is
obtained. Then tighten the power steering pump
fixing bolts.
2. Magnetic Clutch Harness Connector
1. Air Duct (Turbo to air cleaner)
Power steering
pump pulley
Tension adjustment
bolt
Crank pulley Drive beltCompressor98N{10kgf}
14™17mm
(0.55™
0.67 in.)
850RY00002

AIR CONDITIONING 1B Ð 31
REMOVAL
Preparation:
·Battery ground cable
·Discharge and recover refrigerant (Refer to
ÒREFRIGERANT RECOVERYÓ in this section)
1. Air Duct (Turbo to air cleaner)
Cover up the air duct connecting portion to prevent
foreign materials from getting into the turbo and the
air cleaner.
2. Magnetic Clutch Harness Connector
3. Drive Belt
Loosen the power steering pump unit fixing bolts,
then loosen the drive belt adjustment bolt and
remove the drive belt.
4. Refrigerant Line Connector
5. Compressor
CompressorTension adjustment bolt
Tension pally
14~17mm
(0.55-0.67in)
98N{10kgf}
Crank shaft pully
INSTALLATION
5. Compressor
Tighten the compressor fixing bolts to the specified
torque.
Compressor Bolt Torque Nám (kgám / lbáft)
40 (4.1 / 30)
4. Refrigerant Line Connector
·O-rings cannot be reused. Always replace with new
ones.
·Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
·Tighten the refrigerant line connector to the
specified torque.
Refrigerant Line Bolt Torque Nám (kgám / lbáft)
27 (2.8 / 20)
850RY00003

1B Ð 32 AIR CONDITIONING
3. Drive Belt
1) Temporary tighten the power steering pump unit
fixing bolts.
2) Push the drive belt when the force of 98N {10kgf}.,
and adjust the drive belt tension by tightening
drive belt tension adjustment bolt, till the 14 ~17
mm (0.55 ~0.67 in) of deflection of the belt is
obtained. Then tighten the power steering pump
fixing bolts.
2. Magnetic Clutch Harness Connector
1. Air Duct (Turbo to air cleaner)
CompressorTension adjustment bolt
Tension pally
14~17mm
(0.55-0.67in)
98N{10kgf}
Crank shaft pully
850RY00003

00 Ð 8 SERVICE INFORMATION
Checkpoint Possible cause Correction
Booster compensator pipe broken or
crackedReplace the booster compensator
pipe Turbocharger
Exhaust gas leakage from the exhaust
system
Air leakage from the intake systemRepair or replace the related parts
Defective waste gate Repair or replace the waste gare
Defective turbocharger assembly Replace the turbocharger assembly
Blown out cylinder head gasket. Worn
cylinder liner.
Piston ring sticking between the valve and
valve seatReplace the related parts Compression
pressure
Valve clearance improperly adjusted Adjust the valve clearance Valve clearance
Valve spring weak or broken Replace the valve spring Valve spring
Exhaust pipe clogged Clean the exhaust pipe Exhaust system
Open and improperly set adjusting screw
sealAdjust and reseal the adjusting
screw Full load adjusting
screw seal

SERVICE INFORMATION 00 Ð 9
4. EXCESSIVE FUEL CONSUMPTION
5. EXCESSIVE OIL CONSUMPTION
Checkpoint Possible cause Correction
Engine oil Engine oil unsuitable
Too mauch engine oilReplace the engine oil
Correct the engine oil level
Oil seal and gasket Oil leakage from the oilseal and/or the
gasketReplace the oil seal and/or the
gasket
Air breather Clogged air breather Clean the air breather
Intake and exhaust
valveWorn valve stems and valve guides Replace the intake and exhaust
valves and the valve springs
Checkpoint Possible cause Correction
Fuel system Fuel leakage Repair or replace the fuel system
related parts
Air cleaner Clogged air cleaner element Clean or replace the air cleaner
element
Idling speed Poorly adjusted idling speed Adjust the idling speed
Injection nozzle Injection nozzle injection starting pressure
too low
Improper spray condition Adjust or replace the injection
nozzle
Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing
Injection pump Defective Delivery valve resulting is fuel
drippage after fuel injectionReplace the delivery valve
Turbocharger Air leakage from the turbocharger intake
sideRepair the turbocharger intake side
Defective turbocharger assembly Replace the turbocharger assembly
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Compression
pressureBlown out cylinder head gasket. Worn
cylinder liner.
Piston ring sticking between the valve and
valve seatReplace the related parts
Valve spring Valve spring weak or broken Replace the valve spring

00 Ð 10 SERVICE INFORMATION
6. OVERHEATING
7. WHITE EXHAUST SMOKE
Checkpoint Possible cause Correction
Fuel Water particles in the fuel Replace the fuel
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing
Compression
pressureBlown out cylinder head gasket. Worn
cylinder liner.
Piston ring sticking between the valve and
valve seatReplace the related parts
Turbocharger Defective turbocharger Replace the turbocharger
Inlet and exhaust
valves
Valves sealsDefective valve seales.
Worn valves stems and valve guidesReplace the valve seales, the valves,
and the valve guides
Checkpoint Possible cause Correction
Cooling water Insufficient cooling water Replace the cooling water
Fan clutch Oil leakage from the fan clutch Replace the fan clutch
Fan belt Fan belt loose or cracked causing slippage Replace the fan belt
Radiator Defective radiator cap or clogged radiator
coreReplace the radiator cap or clean the
radiator core
Water pump Defective water pump Repair or replace the water pump
Cylinder head and
cylinder body sealing
capDefective searing cap resulting in water
leakageReplace the sealing cap
Thermostat Defective thermostat Replace the thermostat
Cooling system Cooling system clogged by foreign
materialClean the foreign material from the
cooling system
Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing

00 Ð 20 SERVICE INFORMATION
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Engine type
Camshaft type
Cylinder line-type
Number of cylinders
Bore x stroke
Total piston displacement
Compression ratio
Engine weight (dry)
Engine idling speed (Reference)
Compression pressure
Firing order
Injection timing
VALVE SYSTEM
Intake valves
Exhaust valve
Valve clearance at
Oil filter
Oil capacity (Original factory fill or rebuilt engine)
Oil capacity (Service change)
with filter change
without filter change
Oil cooler
Inter cooler
Turbocharger
Control method
Lubrication method
Cooling method
(mm)
(cc)
(to 1)
N (kg/lb)
RPM
open at:
close at:
open at:
close at:
cold
intake:
exhaust:mm (in)Diesel, four cycle water cooled inline
Overhead valve
Dry type
4
95.4 x 107
3,059
20.0
2353 (240/529)(4JG2-NA)
2597 (265/584)(4JG2-T)
750 (4JG2-NA)
720 (4JG2-T)
2940 (30/426)-200
1–3–4–2
1¡A.T.D.C (4JG2-NA)
T.D.C. (4JG2-T)
B.T.D.C. 24¡
A.B.D.C. 55¡
B.B.D.C. 54¡
A.T.D.C. 26¡
0.40 (0.016)
0.40 (0.016)
Full flow and bypass combined type
7.1 liters (6.3 US quarts)
6.0 liters (6.3 US quarts)
5.0 liters (5.3 US quarts)
Water cooled type
Air cooled type
Wastegate control
Pressurized control
Coolant cooled kpa (kg/cm /psi)-rpm
2