1998 ISUZU TROOPER Turbo

ENGINE MECHANICAL 6A – 37
RINSTALLATION
1. Install gasket on the exhaust manifold and tighten
to the specified torque.
Torque : 30 N·m (3.1 kg·m/22 lb ft)
2. Install turbocharger on the exhaust manifold.
Torque : 27 N·m (2.8 kg·m/20.2 lb ft)
3. Install water hoses and oil pipes.
4. Install heat protector to turbocharger.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
5. Install A/C compressor assembly and readjust belt
tensioner.
6. Install the intercooler assembly in the normal
position.
Connect both hoses to turbocharger and intake
manifold.

6A – 38 ENGINE MECHANICAL
TURBOCHARGER
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025R200004
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose(5) Water Hose
(6) Heat Protector
(7) Oil Pipe
(8) Oil Pipe
(9) Gasket

ENGINE MECHANICAL 6A – 39
REMOVAL
1. Remove battery.
2. Drain engine coolant.
3. Remove air cleaner cover with air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove water pipe for turbocharger inlet.
6. Remove oil pipe for turbocharger.
1) Remove eye bolt from turbocharger.
2) Plug oil port on the turbocharger to prevent entry
of foreign materials.
7. Remove oil drain pipe from turbocharger.
8. Remove water outlet pipe.
9. Remove heat protector.
10. Remove exhaust adaptor.
11. Remove turbocharger assembly from exhaust
manifold.
For Europe
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6A – 40 ENGINE MECHANICAL
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque : 27 N·m (2.8 kg·m/20.2 lb ft)
2. Install exhaust adaptor.
Torque : 27 N·m (2.8 kg·m/20.2 lb ft)
3. Install heat protector.
4. Install water outlet pipe with gasket.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
5. Install turbocharger oil drain pipe.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)6. Install oil supply pipe to turbocharger.
1) Fill with 100 cc engine oil at the turbocharger oil
supply hole before installing the oil pipe.
2) Turn the turbocharger by hand to lubricate
turbocharger shaft.
3) Install oil supply pipe with new gasket to the
turbocharger and tighten oil supply pipe bolts to
the specified torque.
Torque : 22 N·m (2.2 kg·m/15.9 lb ft) for M10
54 N·m (5.5 kg·m/39.8 lb ft) for M14
7. Install water inlet pipe with new gasket, tighten to
the specified torque.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
8. Install intercooler assembly.
Refer to “Intercooler” in this manual.
9. Install air cleaner cover with air duct, connect both
side hoses.
10. Fill with engine coolant.
11. Install the battery and connect battery cables.
For Europe
025R200007
For Europe
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For Europe
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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
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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.
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6A – 60 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drivebelt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
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Legend
(1) Adjuster
(2) Tappet
(3) Split Collar
(4) Spring Seat Upper
(5) Valve Spring(6) Spring Seat Lower
(7) Valve Stem Seal
(8) Valve Guide
(9) Valve Seat
(10) Valve

6A – 66 ENGINE MECHANICAL
INSTALLATION
1. Valve stem seal
1) Use the special tool to install the stem seal to the
valve guide.
Stem Seal Installer: 5-8840-2033-0
2. Valve spring.
1) Install the lower valve seat spring, valve spring,
then the upper valve spring seat.
2) Use valve spring compressor to compress the
spring then install the split collar.
Valve spring compressor: 5-8840-2441-0
NOTE: Make sure the split collar installs completely.
3. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
4. Install the camshaft carrier with camshaft.
Refer to “Camshaft” in this manual.
5. Install oil rail assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector assembly.
Refer to “Oil rail and injector” in this manual.
7. Install the injector harness assembly.
Refer to “Injector” in this manual.
8. Reconnect harness connecter to oil pressure
sensor and oil temperature sensor on the oil rail.
9. Reconnect Injector harness connecter to injector.
Refer to “Injector” in this manual.
10. Install cylinder head cover with gasket.
Refer to “Cylinder Head Cover” in this manual.
11. Install glow plug with specified torque.
Torque: 15 N·m (1.5 kg·m / 10.8 lb ft)
12. Install the intake manifold assembly.
Refer to “Intake Manifold” in this manual.
13. Install the fuel pipe.14. Install the water pipe between the cylinder head
and water pump.
Torque: 20 N·m (2.0 k·m / 14.5 lb ft)
15. Install the front plate.
16. Install the camshaft pulley.
Refer to “Timing Gear” in this manual.
17. Install timing belt and set the tensioner.
Refer to “Timing Belt” in this manual.
18. Install CMP sensor bracket.
Torque: 20 N·m (2.0 kg·m / 14.5 lb ft)
19. Install timing belt cover.
Torque: 9 N·m (0.9 kg·m / 6.5 lb ft)
20. Fill the oil rail with engine oil then immediately
install the high pressure oil pipe with the specified
torque.
Torque: 80 N·m (8.1 kg·m / 57.9 lb ft)
21. Install the noise insulator cover.
22. Reconnect hose between thermostat and radiator.
23. Install turbocharger assembly.
Refer to “Turbocharger” in this manual.
24. Install water hose and oil pipe for turbocharger.
Refer to “Turbocharger” in this manual.
25. Install the valve assembly and install heat protector.
26. Install generator and set the fan belts.
27. Install A/C compressor bracket, compressor
assembly and set drive belt.
28. Reconnect harness connector around cylinder
head.
29. Reconnect vacuum hose to EGR valve.
30. Reconnect PCV hose.
31. Install oil level gauge guide assembly.
32. Install intercooler assembly.
Refer to “Intercooler” in this manual.
33. Install the air duct assembly.
34. Fill engine coolant.
35. Connect battery ground cable.
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