1998 ISUZU TROOPER stop start

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)

6A±11
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine overheatingLevel of Engine Coolant too lowReplenish
Fan clutch defectiveReplace
Incorrect fan installedReplace
Thermostat defectiveReplace
Engine Coolant pump defectiveCorrect or replace
Radiator cloggedClean or replace
Radiator filler cap defectiveReplace
Level of oil in engine crankcase too
low or wrong engine oilChange or replenish
Resistance in exhaust system
increasedClean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrectReplace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shortedCorrect or replace
Cylinder head gasket damagedReplace
Engine overcoolingThermostat defectiveReplace (Use a thermostat set to
open at 82
C (180
F))
Engine lacks compressionÐÐÐÐRefer to Hard Start
OthersTire inflation pressure abnormalAdjust to recommended pressures
Brake dragAdjust
Clutch slippingAdjust or replace
Level of oil in engine crankcase too
highCorrect level of engine oil
Exhaust Gas Recirculation Valve
defectiveReplace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and othermoving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Condition
Possible causeCorrection
Noise from crank journals or from
crank bearings
(Faulty crank journals and crankOil clearance increased due to worn
crank journals or crank bearingsReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
yj
bearings usually make dull noise that
becomes more evident when
accelerating)Crankshaft out of roundReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seizedCrank bearing seized. Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defectivebearing by listening for abnormal noise that stops when
spark plug is shorted out.

6A±16
ENGINE MECHANICAL
Lubrication Problems
ConditionPossible causeCorrection
Oil pressure too lowWrong oil in useReplace with correct engine oil
Relief valve stickingReplace
Oil pump not operating properlyCorrect or replace
Oil pump strainer cloggedClean or replace strainer
Oil pump wornReplace
Oil pressure gauge defectiveCorrect or replace
Crankshaft bearing or connecting
rod bearing wornReplace
Oil contaminationWrong oil in useReplace with correct engine oil
Oil filter cloggedReplace oil filter
Cylinder head gasket damageReplace gasket
Burned gases leakingReplace piston and piston rings or
cylinder body assembly
Oil not reaching valve systemOil passage in cylinder head or
cylinder body cloggedClean or correct
Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine oil.
a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the ªMaintenance and Lubricationº section
of this manual.
2. Check the engine oil level.
The level should fall somewhere between the ªADDº
and the ªFULLº marks on the oil level dipstick.
If the oil level does not reach the ªADDº mark on the
oil level dipstick, engine oil must be added.3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal
operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
392±550 kPa (56.9±80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

6A±50
ENGINE MECHANICAL
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 N´m (2.2 Kg´m/16 lb ft)
M10 bolts : 43 N´m (4.4 Kg´m/32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22N´m (2.2 Kg´m/16 lb ft)
M10 bolts : 46 N´m (4.7 Kg´m/34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
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Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable and automatic cruise
control cable to throttle valve on common chamber.
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Legend
(1) Throttle Valve Assembly
(2) Throttle Lever
(3) Idle Air Control Valve
(4) Throttle Position Sensor
27. Install engine hood to the original position.

Refer to installation procedure for Body section in
this manual.
Accelerator pedal cable adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while fully closing the throttle
valve.
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.

6B±6
ENGINE COOLING
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the ªMINº
and ªMAXº lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the ªMAXº line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.
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2. Remove the radiator cap.
WARNING: T O AV O I D T H E D A N G E R O F B E I N G
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to ªMAXº line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to ªPº (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 ~ 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.9. After the engine has cooled, replenish with EC up to
the ªMAXº line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound from
the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to
10.

ENGINE COOLING6B±11
Cap tester: 5±8840±0277±0
Adapter: 5±8840±2603±0
110RS005
Installation
1. Install rubber cushions on both sides of radiator
bottom.
2. Install radiator assembly with hose, taking care not to
damage the radiator core with a fan blade.
3. Install bracket (6) and support the radiator upper tank
with the bracket (5) and secure the radiator.
4. Connect reserve tank hose (4).
5. Install lower fan guide (3).
6. Connect radiator inlet hose and outlet hose to the
engine.
7. Connect oil cooler hose (1) to automatic
transmission.
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8. Connect battery ground cable.
9. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.
111RS001Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.
1. Make sure that the engine is cool.
2. Open radiator cap pour coolant up to filler neck.
3. Pour coolant into reservoir tank up to ªMAXº line.
4. Tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
WARNING: WHEN THE COOLANT IS HEATED TO A
HIGH TEMPERATURE, BE SURE NOT TO LOOSEN
OR REMOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A
PIECE OF THICK CLOTH ON THE CAP AND LOOSEN
THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER.
5. After tightening radiator cap, warm up the engine
at about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
circulate also into heater water system.
6. Check to see the thermostat has opened through
the needle position of water thermometer,
conduct a 5±minute idling again and stop the
engine.
7. When the engine has been cooled, check filler
neck for water level and replenish if required.
Should extreme shortage of coolant is found,
check the cooling system and reservoir tank hose
for leakage.
8. Pour coolant into reservoir tank up tp ªMAXº line.

6C±5
ENGINE FUEL
Installation
1. Install the fuel filter in the proper direction.
2. Install fuel filter holder fixing bolt.
3. Connect fuel hoses on engine side(1) and fuel tank
side(2).
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4. Install fuel filler cap
5. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel leakage.
In±Tank Fuel Filter
The filter is located on the lower end of fuel pickup tube in
the fuel tank. It prevents dirt from entering the fuel pipe
and also stops water unless the filter is completely
submerged in the water. It is a self cleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Fuel Pump Flow Test
If reduction of fuel supply is suspected, perform the
following checks:
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe and
hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing or
clogging.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.4. Connect the pump relay terminals with a jumper
wire(1) as shown and start the fuel pump to measure
delivery.
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CAUTION: Never generate sparks when connecting
a jumper wire.
Delivery
Delivery
15 seconds0.38 liters minimum
If the measure value is out of standard, conduct the
pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E
ªFuel Control Systemº.

6D3±2STARTING AND CHARGING SYSTEM
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts of
magnetic switch are closed, and the armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.