height adjustment ISUZU TROOPER 1998 Service Repair Manual

00 – 6 SERVICE INFORMATION
Problem Possible Cause Correction
GENERAL TROUBLESHOOTING (CONT.)
Wandering or Poor
Steering Stability
Erratic Steering When
Bracking
Low or Uneven Trim
Height
Suspension Bottoms
Body Leans
Cupped Tires1. Mismatched or unevenly worn tires.
2. Loose steering linkage ball joints.
3. Faulty shock absorbers.
4. Loose stabilizer bar.
5. Broken or sagging springs.
6. Steering gear misadjustment.
7. Improper wheel alignment.
1. Worn wheel bearings.
2. Broken or sagging springs.
3. Leaking caliper.
4. Warped discs.
5. Badly worn brake pads.
6. Tires are inflated unequally.
1. Broken or sagging springs.
2. Vehicle overloaded.
3. Incorrect springs.
1. Vehicle overloaded.
2. Faulty shock absorber.
3. Incorrect, broken or sagging springs.
1. Loose stabilizer bar.
2. Faulty shock absorbers, struts or
mounting.
3. Broken or sagging springs.
4. Vehicle overloaded.
1. Worn wheel bearings.
2. Excessive tire or wheel runout.
3. Worn ball joints.
4. Tire out of balance.Replace tire or inflate tires to
proper pressure.
Replace ball joints.
Replace shock absorber.
Tighten or replace stabilizer bar
or bushings.
Replace spring (pairs).
Check or adjust steering gear.
Adjust wheel alignment.
Replace wheel bearings.
Replace spring (pairs).
Repair or replace caliper.
Replace brake disc.
Replace brake pads.
Inflate tires to proper pressure.
Replace springs (In pairs)
Reduce load.
Adjust or replace torsion bar.
Reduce load.
Replace shock absorber.
Replace springs.
Tighten stabilizer bar bolts or
replace bushings.
Replace shock absorber.
Replace springs (In pairs)
Reduce load.
Replace wheel bearings.
Replace tire or wheel.
Replace ball joints.
Adjust tire balance.

FRONT END ALIGNMENT 2A – 1
SECTION 2A
FRONT END ALIGNMENT
CONTENTS
PAGE
General Description .......................................................................................................... 2A – 2
Definition of Terms ....................................................................................................... 2A – 2
On-Vehicle Service............................................................................................................ 2A – 3
Inspection ..................................................................................................................... 2A – 3
Trim Height Adjustment .............................................................................................. 2A – 3
Caster Adjustment ....................................................................................................... 2A – 4
Camber Adjustment ..................................................................................................... 2A – 4
Toe-in Adjustment ........................................................................................................ 2A – 5
Maximum Steering Angle Adjustment ...................................................................... 2A – 5

INSPECTION
Before making any adjustments affecting caster, camber
or toe-in, the following front end inspection should be
made.
INSPECT
1. Tires for proper inflation pressure. Refer to “Wheels
and Tires” in section 3E.
2. Front wheel bearings for proper adjustment. Refer to
“Front Wheel Drive” in section 4C.
3. Ball joints, tie rod ends and relay rods. If excessive
looseness is noted, correct before adjusting. Refer to
“Steering Linkage” in section 2A.
4. Wheel and tires for run-out. Refer to “Wheels and
Tires”in section 3E.
5. Trim height. If not within specifications, the
correction must be made before adjusting caster.
6. Steering gear for looseness at the frame.
7. Shock absorbers for leaks or any noticeable noise.
Refer to “Front Suspension” in section 3C.
8. Control arms or stabilizer bar attachment for
looseness. Refer to “Front Suspension“ in section 3C.
9. Alignment equipment. Follow the manufacturer’s
instructions.
10. Level of the vehicle. The vehicle must be on a level
surface.
TRIM HEIGHT ADJUSTMENT
Adjust the trim height by means of the adjusting bolt on
the height control arms.
CAUTION:
When adjusting front end alignment, be sure to begin
with trim height as trim height adjustment may change
other adjusted alignments.
1. Check and adjust the tire inflation pressures.
2. Park the vehicle on a level ground and move the front
of the vehicle up and down several times to settle the
suspension.
3. Make necessary adjustment with the adjusting bolt
on the height control arms.
Trim Height(Z) mm(in)
139 ± 5 (5.47 ± 0.2)FRONT END ALIGNMENT 2A – 3
ON-VEHICLE SERVICE

POWER ASSISTED BRAKE SYSTEM 5C – 13
CHECKING BRAKE PEDAL HEIGHT
The push rod serves as the brake pedal stopper when
the pedal is fully released. Brake pedal height
adjustment should be performed as follows:
Adjust Brake Pedal
1. Measure the brake pedal height after making sure
the pedal is fully returned by the pedal return
spring.
Pedal height (L2) must be measured after starting
the engine and revving it several times.
Pedal Free Play (L1) mm (in)
6 – 10 (0.23 – 0.39)
Pedal Height (L2) mm (in)
LHD RHD
208 – 218 211 – 221
(8.19 – 8.58) (8.31 – 8.70)
NOTE:
Pedal free play (L1) must be measured after turning
off the engine and stepping on the brake pedal firmly
five times or more.
2. If the measured value is not within the above
range, adjust the brake pedal as follows:
a) Disconnect the stop light switch connector.
b) Loosen the stop light switch lock nut.
c) Rotate the stop light switch so that it moves
away from the brake pedal.
d) Loosen the lock nut on the push rod.
e) Adjust the brake pedal to the specified height
by rotating the push rod in the appropriate
direction.
f) Tighten the lock nut to the specified torque.
Lock Nut Torque N·m (kg·m/lb·ft)
20 (2.0 / 15)
g) Adjust the stop light switch to the specified
clearance (between switch housing and brake
pedal) by rotating the switch housing.
Clearance mm (in)
0 – 0.2 (0 – 0.008)
NOTE:
While adjusting the installation of the stoplight
switch, make sure that the threaded part of the
stoplight switch does not push the brake pedal.
h) Tighten the stop light switch lock nut.
i) Connect the stop light switch connector.
Switch
Floor panel
(L3)
(A)
(L2)(L1)
Lock nut
(A)

5C – 46 POWER ASSISTED BRAKE SYSTEM
3. Yoke Clevis
2. Vacuum Booster
•Refer to Vacuum Booster Assembly in this
section.
1. Master Cylinder
1) Refer to Master Cylinder Assembly in this Section.
2) After installation, perform brake pedal check and
adjustment. Refer to Checking Brake Pedal Height
/ Travel in this section.

6A±27
ENGINE MECHANICAL
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
nuts then disconnect exhaust front pipe.
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
4. Remove heat protector two fixing bolts then the heat
protector.
5. Remove exhaust gas recirculation (EGR) pipe fixing
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.
056RW001
Legend
(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe
6. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
Torque : 57 N´m (5.8 Kg´m/42 lb ft)
2. Install the EGR pipe, tighten bolt and nut on exhaust
manifold to specified torque.
Torque : 28 N´m (2.9 Kg´m/21 lb ft)
Tighten nut to EGR valve to the specified torque.
Torque : 44 N´m (4.5 Kg´m/33 lb ft)
Tighten the bolt for EGR pipe bracket to specified
torque.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
3. Install heat protector
4. 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)
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.

ENGINE MECHANICAL 6A Ð 3
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
·Cylinder head gasket and mating surfaces for leaks,
corrosion and blow-by. If the gasket has failed,
determine the cause;
Ð Improper installation
Loose or warped cylinder head
Ð Insufficient torque on head bolts
Ð Warped case surface
1. Cylinder head bolts for damaged threads or stretch-
ing and damaged heads caused by improper use of
tools.
CAUTION:
Suspected bolts must be replaced.
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:
Do not attempt to weld the cylinder head. Replace it.
4. Cylinder head deck, intake and exhaust manifold
mating surfaces for flatness.
These surfaces may be re-conditioned by milling. If
the surfaces are Òout of flatÓ by more than specifica-
tion, the surface should be grinded to within specifi-
cations. If more than limit of specification, it should
be replaced.
5. Water jacket sealing plugs seating surfaces.
6. Use a straight edge and a feeler gauge to measure
the manifold cylinder head fifting face warpage.
Regrind the exhaust manifold cylinder head fifting
surfaces if the measured values are between the
specified limit and the standard.
If the measured values exceed the specified limit, the
manifold must be replaced.
Cylinder Head
Lower Face
Warpagemm (in)
0.05 (0.0020)
or less0.20 (0.0079)
Cylinder Head
Height92 (3.6220)
–
Standard Limit
Standard Limit
mm(in)
0.05 (0.0020) or less 0.20 (0.0079) Exhaust Manifold Warpage

6A Ð 8 ENGINE MECHANICAL
At installed
height 38.9mm
(1.5in)StandardN(Kg/lb)
Limit
294.0 (30/66.1)257.9 (26.3/57.9)
Valve spring
CAUTION:
Visually inspect the valve springs and replace them if
damage or abnormal wear is evident.
1. Free height
·Measure the free height of the springs. The springs
must be replaced if the height is below the specified
limit.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
2. Squareness
·Measure the valve spring squareness with a steel
square.
·Replace the valve springs if the measured value
exceeds the specified limit.
3. Spring tension
·Use a spring tester to compress the springs to the
installed height. Measure the compressed spring
tension.
Replace the springs if the measured tension is
below the specified limit.
Valve Guide
CAUTION:
Taking care not to damage the valve seat contact surface,
when removing carbon adhering to the valve head.
Carefully inspect the valve stem for scratching or
abnormal wear. If these conditions are present, the valve
and the valve guide must be replaced as a set.
Limitmm(in)
1.7 (0.0669)
Standard Limit
48.0 (1.8898) 47.100 (1.8543)mm(in)

ENGINE MECHANICAL 6A Ð 15
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
8. Camshaft
9. Tappet
1. Measure the Camshaft Thrust Clearance.
¥ Use a dial indicator to measure the camshaft end
play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified
limit, the thrust plate must be replaced.
2. Camshaft Journal Diameter
¥ Use a micrometer to measure each camshaft
journal diameter in two directions (1 and 2). If the
measured value is less than the specified limit,
the camshaft must be replaced.
3. Cam Height
¥ Measure the cam height H with a micrometer. If
the measured value is less than the specified
limit, the camshaft must be replaced.
Standard Limit
mm(in)
49.945-49.975 (1.9663-1.9675) 49.60 (1.9528) Journal Diameter
Standard Limit
mm(in)
42.02 (1.6543) 41.65 (1.6398) Cam Height
Standard Limit
mm(in)
0.08 (0.0031) 0.2 (0.0079) Camshaft End Play

6A Ð 44 ENGINE MECHANICAL
INSPECTION REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
1. Remove the 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 oil pan installation surface seal.
3. Wipe the cylinder block clean.
Cylinder Liner Projection Inspection
1. Hold a straight edge 1 along the top edge of the cylinder
liner to be measured.
2. Use a feeler gauge 2 to measure each cylinder liner
projection.
The difference in the cylinder liner projection height
between any two adjacent cylinders must not exceed
0.03 mm (0.0012 in).
0.0 – 0.1 (0.0000 – 0.0039)
mm(in.) Standard
Flatness
1. Remove the cylinder body dowel.
2. Set the cylinder liner remover to the cylinder liner.
3. Check that the remover shaft ankle is firmly gripping the
cylinder liner bottom edge.
4. Slowly turn the remover shaft handle counterclockwise
to pull the cylinder liner free.
Cylinder Liner Remover Ankle: 5-8840-2304-0
Cylinder Liner Remover: 9-8523-1169-0
NOTE:
Take care not to damage the cylinder body upper during the
cylinder liner removal procedure.
5. Use a straight edge 1 and a feeler gauge 2 to measure the
four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceed the limit, the cylinder
body must be replaced.
0.20 (0.0079)
mm(in.) Limit