1998 ISUZU TROOPER electrical system

POWER ASSISTED BRAKE SYSTEM 5C – 39
MASATER CYLINDER ASSEMBLY
6
21
5
3
4a
4b
Removal Steps
1. Electrical connector
2. Brake pipes
3. 2 attaching nuts
4a. P&B valve and bracket
4b. 3-way connector and bracket (Vehicle
with LSPV only)
5. Master cylinder
6. Spacer and 2 gaskets
Installation Steps
To install, follow the removal steps in the
reverse order.
This illustration is based on the LHD model.
330RW015

5C – 40 POWER ASSISTED BRAKE SYSTEM
REMOVAL
CAUTION:
When removing master cylinder from vacuum
booster, be sure to get rid of the internal negative
pressure of the vacuum booster (by, for instance,
disconnecting vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing master cylinder, further, do not hold
the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
1. Electrical Connector
2. Brake Pipes
•After disconnecting the brake pipe, cap or tape
the openings of the brake pipe to prevent the
entry of foreign matter.
3. 2 Attaching Nuts
4a. P & B Valve and Bracket
4b.3-way Connector and Bracket (Vehicle with LSPV
Only)
5. Master Cylinder
6. Spacer and 2 Gaskets
INSTALLATION
6. Spacer and 2 Gaskets
5. Master Cylinder
•When replacing the master cylinder or vacuum
booster or both, always measure the vacuum
booster push rod protrusion and adjust it as
necessary. (Refer to Vacuum Booster Assembly in
this section.)
4a. P & B Valve and Bracket
4b.3-way Connector and Bracket (Vehicle with LSPV
Only)
3. 2 Attaching Nuts
•Tighten the attaching nuts to the specified torque.
Attaching Nut Torque N·m (kg·cm / lb·in)
13 (130 / 113)
2. Brake Pipes
•Tighten the brake pipe to the specified torque.
Brake Pipe Torque N·m (kg·m / lb·ft)
Master Cylinder Side Others
12 (1.2 / 9) 16 (1.6 / 12)
1. Electrical Connector

6A±1
ENGINE MECHANICAL
ENGINE
CONTENTS
Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical 6D1. . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 6D2. . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System 6D3. . . . . . . . . . . . Driveability and Emissions 6E. . . . . . . . . . . . . . . .
Engine Exhaust 6F. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6G. . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System 6H. . . . . . . . . . . .
Inducton 6J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL
CONTENTS
Service Precaution 6A±2. . . . . . . . . . . . . . . . . . . . . .
General Description 6A±3. . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis 6A±4. . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH 6A±18. . . . . . . . . . . . . . . . .
Removal 6A±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH 6A±21. . . . . . . . . . . . . . . . .
Removal 6A±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber 6A±24. . . . . . . . . . . . . . . . . . . . . .
Removal 6A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH 6A±26. . . . . . . . . . . . . . . . . . . . .
Removal 6A±26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH 6A±27. . . . . . . . . . . . . . . . . . . .
Removal 6A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley 6A±28. . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 6A±29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A±37. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring and
Valve Guide 6A±39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod 6A±40. . . Removal 6A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A±42. . . . . . . . . . . .
Removal 6A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal 6A±47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly 6A±48. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A±52. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts 6A±52. . . . .
Disassembly 6A±52. . . . . . . . . . . . . . . . . . . . . . . . . .
Clean 6A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±53. . . . . . . . . . . . . . . . . .
Reassembly 6A±53. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide 6A±56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide and Associated Parts 6A±56. . . . . . .
Disassembly 6A±56. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±57. . . . . . . . . . . . . . . . . .
Reassembly 6A±60. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustments 6A±61. . . . . . . . . . . . .
Camshaft 6A±63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts 6A±63. . . . . . . . .
Disassembly 6A±63. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±64. . . . . . . . . . . . . . . . . .
Reassembly 6A±66. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 6A±69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts 6A±69. . . . . . . .
Disassembly 6A±69. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±70. . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±71. . . . . . . . . . . . . . . . . .
Reassembly 6A±73. . . . . . . . . . . . . . . . . . . . . . . . . .

6A±3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.

A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.

Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.

At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.

Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:

When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick±up unit.

The 12±volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.

Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die±cast casting
for 75
V±type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent±roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V±type design. The ports are cross±flow
type.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast±iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid±type oil pump driven by
the crankshaft is fed through full±flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A±4
ENGINE MECHANICAL
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Possible causeCorrection
Headlights go out or dim
considerably
Battery run down or under chargedRecharge or replace battery
considerablyTerminals poorly connectedClean battery posts and terminals
and connect properly
Starting motor coil circuit shortedOverhaul or replace
Starting motor defectiveOverhaul or replace
2. Ignition Trouble Ð Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an igniton coil from any spark plug. Connect
the spark plug tester 5±8840±0607±0, start the engine,
and check if a spark is generated in the spark plug tester.
Before starting the engine, make sure that the spark plugtester is properly grounded. To avoid electrical shock, do
not touch the part where insulation of the igniton coil is
broken while the engine is running.
Condition
Possible causeCorrection
Spark jumps across gapSpark plug defectiveClean, adjust spark gap or replace
Ignition timing incorrectRefer to Ignition System
Fuel not reaching fuel injector(s) or
engineRefer to item 3 (Trouble in fuel
system)
Valve timing incorrectAdjust
Engine lacks compressionRefer to item 4 (Engine lacks
compression)
No sparking takes placeIgnition coil disconnected or brokenConnect properly or replace
Electronic Ignition System with
moduleReplace
Poor connections in engine harnessCorrect
Powertrain Control Module cable
disconnected or defectiveCorrect or replace
3. Trouble In Fuel System
Condition
Possible causeCorrection
Starting motor turns over and spark
occurs but engine does not start
Fuel tank emptyFill
occurs but engine does not start.Water in fuel systemClean
Fuel filter cloggedReplace filter
Fuel pipe cloggedClean or replace
Fuel pump defectiveReplace
Fuel pump circuit openCorrect or replace
Evaporative Emission Control
System circuit cloggedCorrect or replace
Multiport Fuel Injection System faultyRefer to ªElectronic Fuel Injectionº
section

ENGINE ELECTRICAL6D1±1
ENGINE
ENGINE ELECTRICAL
CONTENTS
Service Precaution 6D1±1. . . . . . . . . . . . . . . . . . . . . .
Battery 6D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D1±2. . . . . . . . . . . . . . . . . . . .
Diagnosis 6D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging 6D1±3. . . . . . . . . . . . . . . . . . . . . . Jump Starting 6D1±3. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal 6D1±4. . . . . . . . . . . . . . . . . . . . . .
Battery Installation 6D1±4. . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D1±5. . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

ENGINE ELECTRICAL6D1±3
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE ± The battery is
good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED ±
Replace battery.
ESTIMATED TEMPERATURE
MINIMUM
VOLTAGE

F
CV
70219.6
60169.5
50109.4
4049.3
30±19.1
20±78.9
10±128.7
0±188.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
THE FOLLOWING:
1. Serious personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the ªPARKº
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the ªNEUTRALº position.
Turn ªOFFº the ignition.
Turn ªOFFº all lights and any other accessory
requiring electrical power.
2. Look at the built±in hydrometer.
If the indication area of the built±in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing
the charging procedure.
Be sure that the booster battery has a 12 volt rating.

6D2±4
IGNITION SYSTEM
Spark Plug
Removal
1. Remove spark plugs.
Inspection and Repair
The spark plug affects entire engine performance and
therefore its inspection is very important.

Check electrode and insulator for presence of cracks,
and replace if any.

Check electrode for wear, and replace if necessary.

Check gasket for damage, and replace if necessary.

Measure insulation resistance with an ohmmeter, and
replace if faulty.

Adjust spark plug gap to 1.0 mm (0.04 in) ~ 1.1 mm
(0.043 in).

Check fuel and electrical systems if spark plug is
extremely dirty.

Use spark plugs having low heat value (hot type plug)
if fuel and electrical systems are normal.

Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely burned.
Sooty Spark Plugs
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance.
Possible causes:

Too rich mixture

Presence of oil in combustion chamber

Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:

Too lean mixture

Improper heat value
Measuring Insulation Resistance

Measure insulation resistance using a 500 volt
megaohm meter.

Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 M
or more
011RS010
Cleaning Spark Plugs

Clean spark plugs with a spark plug cleaner.

Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.

After spark plug is thoroughly cleaned, check
insulator for presence of cracks.

Clean threads and metal body with a wire brush.

File the electrode tip if electrode is extremely worn.

Bend the ground electrode to adjust the spark plug
gap.
011RS011
Installation
1. Spark plugs

Tighten spark plugs to the specified torque.
Torque: 18 N´m (1.8 Kg´m/13 lb ft)