remove seats ISUZU TROOPER 1998 Service Repair Manual

3E – 4 WHEELS AND TIRES
TIRES
REPLACEMENT
When replacement is necessary, the original metric size
should be used. Most metric tire sizes do not have exact
corresponding alphanumeric tire sizes. It is recommended
that new tires be installed in pairs on the same axle. If
necessary to replace only one tire, it should be paired with
tire having the most tread, to equalize braking traction.
CAUTION:
Do not mix different types of tires such as radial, bias and
bias-belted tires except in emergencies, because vehicle
handling may be seriously affected and may result in loss
of control.
TIRE MOUNTING
Remove valve cap on valve stem and deflate the tire.
Then use a tire changing machine to mount or dismount
tires.
Follow the equipment manufacturer’s instruction. Do not
use hand tools or tire lever alone to change tires as they
may damage the tire beads or wheel rim.
TIRE DISMOUNTING
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, and light rust.
Before mounting a tire, the bead area should be well
lubricated with an approved tire lubricant.
After mounting, inflate the tire to 196 kPa (28 psi) so that
beads are completely seated. Inflate the air to specified
pressure and install valve cap to the stem
WARNING:
NEVER STAND OVER TIRE WHEN INFLATING. BEAD MAY
BREAK WHEN BEAD SNAPS OVER RIM’S SAFETY HUMP
AND CAUSE SERIOUS PERSONAL INJURY.
NEVER EXCEED 240 kPa (35 psi) PRESSURE WHEN
INFLATING. IF 240 kPa (35 psi) PRESSURE WILL NOT
SEAT BEADS, DEFLATE, RE-LUBRICATE AND RE-INFLATE.
OVER INFLATION MAY CAUSE THE BEAD TO BREAK AND
CAUSE SERIOUS PERSONAL INJURY.
TIRE REPAIR
There are many different materials on the market used to
repair tires.
Manufacturers have published detailed instructions on
how and when to repair tires. These instructions can be
obtained from the tire manufacturer if they are not
included with the repair kit.
UNIT REPAIR

6A±53
ENGINE MECHANICAL
2. Remove camshaft bracket fixing bolt (5), camshaft
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5±8840±2446±0 valve spring compressor
and 5±8840±2547±0 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
Inspection and Repair
1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blow±by. If the gasket has failed,
determine the cause.
± Insufficient torque on head bolts.
± Improper installation
± Loose or warped cylinder head
± Missing dowel pins
± Warped case surface
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.

Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are ªout of flatº by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)011RW019
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 N´m (1.8 Kg´m/13 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5±8840±2443±0 gear spring lever to turn sub
gear to right direction until the M5 bolt aligns with
the hole between camshaft driven gear and sub
gear.

6A Ð 26 ENGINE MECHANICAL
8. Crankshaft Rear Oil Seal
·With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover : 5-8840-2362-0
9. Crankcase Assembly
·Refer to ÒCrankcaseÓ in Section 6A2.
10. Oil Pump Assembly
11. Piston Cooling Oil Pipe
12. Piston and Connecting Rod Assembly
13. Main Bearing Cap
14. Crankshaft
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
1. Crankshaft
Thrust clearance
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified limit, re-
place the thrust bearing as a set.
Standard Limit
mm(in)
0.10 (0.0039) 0.30 (0.0118)
167 (17/123)N·m(kg·m/lb·ft)
2. Main bearing clearance
1) Remove the main bearing caps in the sequence
shown in the illustration
Arrange the removed main bearing caps in the
cylinder number order.
2) Remove the crankshaft. Remove the main
bearings.
3) Clean the upper and lower bearings as well as the
crankshaft main journal.
4) 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.
5) Set the upper bearings and the thrust washers to
their original positions. Carefully install the
crankshaft.
6) Set the lower bearings to the bearing cap original
position.
7) Apply plastigage to the crankshaft journal unit as
shown in the illustration.
8) Install the main bearing caps. Apply engine oil to
the bolt threads and the seats. Tighten the bolts
to the specified torque.

6A– 76 ENGINE MECHANICAL
7) Apply plastigage to the crankshaft journal unit as
shown in the illustration.
8) Install the main bearing caps. Apply engine oil to
the bolt threads and the seats. Tighten the bolts
to the specified torque.
Torque: 167 N·m (17 kg·m/123 lb ft)
NOTE: Do not allow the crankshaft to rotate.
9) Remove the main bearing caps.
10) Measure the plastigage width and determine the
oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a
set and/or replace the crankshaft.
11) Clean the plastigage from the bearings and the
crankshaft.
Remove the crankshaft and the bearings.
Standard: 0.031 – 0.063 mm (0.0012 – 0.0025 in)
Limit: 0.11 mm (0.0043 in)3. Run-out
1) Carefully set the crankshaft on the V-blocks.
Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.
Standard: 0.05 mm (0.0020 in) or less
Limit: 0.08 mm (0.0031 in)
Measure the diameter and the uneven wear of
main journal and crank pin.
If the crankshaft wear exceeds the specified
limit, crankshaft must be replaced.
Main journal diameter
Standard: 69.917 – 69.932 mm (2.7526 – 2.7532 in)
Limit: 69.91 mm (2.7524 in)
Crank pin diameter
Standard: 52.915 – 52.930 mm (2.0833 – 2.0839 in)
Limit: 52.90 mm (2.0827 in)
Uneven wear limit
Standard: 0.05 mm (0.0020 in) or less
Limit: 0.08 mm (0.0031 in)
014RW055
014RW077
012RW068

8G±2SEATS
Front Seat Assembly
Front Seat Assembly and Associated Parts
750RX016
Legend
(1) Rear Cover
(2) Front Seat Assembly
(3) Seat Belt Warning Connector/Pretensioner
Harness Connector
(4) Rear Seat Foot Rest (L´W´B)(5) Seat Rail Cover (S´W´B)
(6) Door Sill Plate
(7) Riser Cover (L´W´B)
(8) Seat Slide Cover (S´W´B)
(9) Front Cover
(10) Seat Rail Cover and Hole Cover (S´W´B)
Removal
1. Disconnect the battery ground cable.
2. Remove the front cover.
3. Remove the rear cover.

Remove the cover fixing screw from the rear inner
cover, if this model is equipped with the power
seats.
4. Remove the door sill plate.5. Remove the rear seat foot rest.

Refer to the Rear Seat Foot Rest in this section.
6. Remove the riser cover.
7. Remove the seat belt warning connector (Driver's
side only) or pretensioner harness connector.
8. Remove the front seat assembly.

Disconnect the power seat connector, if this model
is equipped with the power seats.

8G±4SEATS
Disassembly
1. Remove the head rest.
2. Remove the reclining knob.
3. Remove the dial(1) (W/height adjuster).

Remove the side cover fixing screws and the dial
lock spring(2).
750RW025
4. Remove the side cover.
5. Remove the armrest assembly.

Open the armrest fastener and remove the armrest
fixing bolt.
750RS004
6. Remove the trim cover.
7. Remove the pad and frame assembly.
8. Remove the hinge cover.
9. Remove the back board assembly(3).

Pull out the back board while prying the clip (4) of
the back board free from the seat back assembly.
750RW032
10. Remove the reclining device.

Turn up the seat back trim cover in order to remove
the reclining device fixing bolts.
750RS006

SEATS8G±5
11. Remove the seat back assembly.

Remove the clips (2) from the seat heater harness
(1), and separate the seat heater connector (3)
(models with the seat heater).
750RW029

Remove the seat back assembly fixing nut on the
opposite side of the reclining device.
750RS007
12. Remove the guide holder.

Pull the guide holder out by holding the bottom end
of it from the seat back assembly.
13. Remove the trim cover.

Remove the trim cover hog rings from the back side
of the seat back.

With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.14. Remove the pad and frame assembly.
15. Remove the seat heater assembly.
16. Remove the seat adjuster.

Disconnect the release wire(4) and remove the
fixing bolts.
750RW006

Remove the seat belt buckle assembly.
17. Remove the height adjuster.
18. Remove the spacer (W/O height adjuster).
19. Remove the seat cushion assembly.
20. Remove the trim cover.

Remove the trim cover hog rings from the back side
of the seat cushion assembly.

With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
21. Remove the frame assembly.
22. Remove the pad assembly.
23. Remove the seat heater assembly.
Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following point.
1. Tighten the armrest assembly fixing bolts to the
specified torque.
Torque: 18 N´m (1.8 kg´m/13 lb ft)
2. Tighten the reclining device fixing bolts to the
specified torque.
Torque: 47 N´m (4.8kg´m/35 lb ft)

8G±6SEATS
Disassembled View (Short Wheel Base)
750RX018
Legend
(1) Head Rest
(2) Seat Back Assembly
(3) Back Board Assembly
(4) Pad & Frame Assembly
(5) Trim Cover
(6) Guide Holder
(7) Reclining Device
(8) Slide Cover
(9) Reclining Knob
(10) Frame Assembly(11) Pad Assembly
(12) Trim Cover
(13) Walk±in Cover
(14) Walk±in Assembly
(15) Seat Adjuster/Seat Adjuster (W/Pretensioner)
(16) Release Wire
(17) Seat Belt Buckle Assembly
(18) Spacer
(19) Seat Cushion Assembly
(20) Hinge Cover
Disassembly
1. Remove the head rest.
2. Remove the reclining knob.
3. Remove the side cover.
4. Remove the hinge cover.5. Remove the back board assembly.

Pull out the back board while prying the clip of the
back board free from the seat back assembly.

SEATS8G±7
6. Remove the reclining device.

Trun up the seat back trim cover in order to remove
the reclining device fixing bolts.
750RS006

Remove the push nut (2) and disconnect walk-in
cable (3) from reclining device (1).
750RW034
7. Remove the seat back assembly.

Remove the seat back assembly fixing nut on the
opposite side of the reclining device.
750RS007
8. Remove the guide holder.

Pull the guide holder out by holding the bottom end
of it from the seat back assembly.
9. Remove the trim cover.

Remove the trim cover hog rings from the back side
of the seat back.

With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
10. Remove the pad and frame assembly.
11. Remove the walk-in cover.
12. Remove the seat adjuster.

Disconnect the release wire (4) and remove the
fixing bolts.
750RW006

Remove the seat belt buckle assembly.

8G±8SEATS
13. Remove the walk-in assembly (passenger side).
14. Remove the spacer (driver side).
15. Remove the seat cushion assembly.
16. Remove the trim cover.

Remove the trim cover hog rings from the back side
of the seat cushion assembly.

With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
17. Remove the frame assembly.
18. Remove the pad assembly.
Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following point.
1. Tighten the armrest assembly fixing bolts to the
specified torque.
Torque: 18 N´m (1.8 kg´m/13 lb ft)
2. Tighten the reclining device fixing bolts to the
specified torque.
Torque: 47 N´m (4.8kg´m/35 lb ft)