1998 ISUZU TROOPER transmission oil

6A2 Ð 32 4JG2-NA/4JG2-TURBO ENGINE
5. Vacuum Hose
6. Crankcase
·Remove crankcase fixing bolts two fixing bolts for
rear oil seal arch parts on crankcase could be
removed extention universal joint box wrench.
·Remove crankcase by using crankcase seal cutter
to shear sealant off and remove crankcase.
Oil seal cutter: 5-8840-2153-0
NOTE
·DonÕt ply crankcase or you may distort sealing
surface.
·Distorted or damaged crankcase should not by
used.
INSTALLATION
6. Crankcase
·Completely remove all sesidual sealant, lubricant
and moisture from the sealing surface of
crankcase and cylinder block.
·Apply a correct width bead of sealant (TB-1207C or
its equivalent) to contact surface of crankcase
there must be no gaps in the bead.
·Install crankcase with cylinder-block, and tighten
fixing bolts to the specified torque.
5. Vacuum Hose
4. Oil Level Gauge Guide Tube
·Install guide tube to the specified torque.
·Connect blow by hose to guide tube.
3. Oil Pipe Clip Bolts: Vacuum Pump
·Tighten oil pipe clip fixing bolts to the specified
torque.
2. Oil Return Pipe: Turbo.
·Tighten fixing nuts to crankcase to the specified
torque.
1. Transmission Housing Bolts
·Pour engine oil into engine.
·Install battery ground cable.
·Start the engine and check for oil leakage from
crankcase.
19 (1.9/14)N·m (kg·m/lb·ft)
19 (1.9/14)N·m (kg·m/lb·ft)
19 (1.9/14)N·m (kg·m/lb·ft)
8 (0.8/69)N·m (kg·m/lb·in)

6A2 Ð 46 4JG2-NA/4JG2-TURBO ENGINE
REAR OIL SEAL
REMOVAL
1. Transmission Assembly
·Refer to ÒTransmissionÓ removal in section 7.
2. Flywheel
3. 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
INSTALLATION
3. Rear Oil Seal
8. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear and
section with 2 bolts.
2) Insert the oil seal into the peripheral section of the
adapter,
3) Insert the sleeve into the adapter section, and 1)
tighten it with a bolt (M12 x 1.75L = 70) until the
adapter section hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the dimension of
the oil seal section.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-0

6A2 Ð 50 4JG2-NA/4JG2-TURBO ENGINE
18. Vacuum Hose : Vacuum Tank
·Disconnect vacuum hose from vacuum pump
side.
19. Glow Plug Harness
20. Transmission Assembly
·Install special tools (engine hangers) in front right
and left rear sides of cylinder head.
·Front right side; use the ground cable fixing bolt
on A/C compressor bracket.
·Left rear side; fix hanger together with oil cooler
hose clip.
Engine hanger: 5-8840-2032-0
·Left engine carefully by using hoist.
21. Engine Mounting
·Remove fixing bolts (both left and right side)
using extension bar and box wrench at under side
of wheel arches.
22. Engine Assembly
·Install special tools (engine hangers) in left rear
and front right sides of cylinder head.
·Lift engine carefully by using hoist.
·Lift front part of engine higher than rear part of it.
·Take out engine asm taking care not to damage
full pipes, brake pipes and etc.
INSTALLATION
22. Engine Assembly
·Position engine mountings by using hoist.
21. Engine Mounting
·After all fixing bolts (left: two bolts, rights: two
bolts) were inserted to every holes, and engine
asm and tighten fixing bolts to the specified
torque.
40 (4.1/30)N·m(Kg·m/lb·ft)
20. Transmission Assembly
·Refer to transmission installation steps
in section 7.
19. Glow Plug Harness
18 Vacuum Hose: Vacuum Tank
17. Engine Ground Cable
16. Fuel Hose
15. Accelerator Cable
·Refer to accelerater cable installation steps in
section 6C.

ENGINE MECHANICAL 6A – 29
13 Vacuum Hose
1) Disconnect vacuum hose from vacuum pump.
14. Starter Harness
1) Disconnect B terminal and put cable harness
close to chassis side.
2) Disconnect S terminal connector.
15. Engine Harness
1) Disconnect engine harness close to engine side.
16. Fuel Pipe
1) Remove fuel pipe from fuel pump and take care
not to spill fuel and let dust enter.
17. Engine Ground Cable
1) Disconnect ground cable from left rear side of
timing gear case.
18. Vacuum Hose: Vacuum Tank
Disconnect vacuum hose from vacuum pump side.
19. Glow Plug Harness
20. Transmission Assembly
1) Set transmission support tool under the
transmission.
2) Remove transmission rear mount.
3) Remove transmission fixing bolt from rear of
engine assembly except two bolts.
4) Carefully hang up engine assembly with a hoist.
5) Remove remaining two transmission fixing bolts.
6) Remove transmission assembly.
7) Remove heater hose.
8) Disconnect wire harness connector for shift on
the fly.
9) Remove vacuum hose.
21. Prepare Engine Stand
22. Engine Assembly
1) Remove engine mount fixing bolts.
2) Carefully hang up the engine assembly.
3) Take out the engine assembly making sure not
to damage the brake oil pipe and other pipe etc.
INSTALLATION
1. Engine assembly
1) Install engine in mounting position by using
hoist.
2. Transmission Assembly
1) Refer to transmission installation steps in
section 7.
3. Engine Mounting
1) After all fixing bolts (left: two bolts, rights: two
bolts) were inserted in every hole, tighten fixing
bolts to the specified torque.
Torque: 40 N·m (4 kg·m/29 lb·ft)
4. Glow Plug Harness
5. Vacuum Hose
1) Connect Vacuum Hose to Vacuum Pump
6. Engine Ground Cable
7. Fuel Pipe
1) Install fuel pipe to fuel pump.
8. Engine Harness
9. Starter Harness
10. A/C Compressor Assembly
1) Tighten temporarily the fixing bolts (upper and
front lower sides of compressor.)2) Tighten fixing bolt (rear under side of
compressor) to the specified torque.
3) Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.
Torque: 40 N·m (4 kg·m/29 lb·ft)
Legend
(1) Tensioner
(2) Bolt
(3) Bracket
(4) A/C compressor
(5) Bolt
11. A.C Generator Harness
12. Engine Ground Cable
1) Tighten ground cable to A/C compressor
bracket.
13. Air Cleaner cover & Duct
14. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
15. Radiator Assembly
1) Install rubber cushion in under left and right part
of radiator and position radiator.
2) Fix radiator with bracket.
16. Cooling Fan Assembly
1) Install cooling fan assembly and tighten fixing
bolts to the specified torque.
Torque: 8 N·m (0.8 kg·m/5.8 lb ft)
17. Fan Shroud
18. Radiator Hose
1) Connect upper and lower hose to engine side.
2) Pour coolant into radiator.
19. Install battery.
20. Connect window washer hose and install engine
hood.
1
2
3
4
5
'PS
&VSPQF
F06R200005

6A – 72 ENGINE MECHANICAL
CRANK CASE
REMOVAL
1. Drain engine oil.
2. Remove transmission assembly.
3. Remove crankshaft damper pulley.
4. Remove timing belt cover, timing belt, pulley and
front plate.
5. Remove timing gear case cover.
6. Remove timing gears.
NOTE: Do not forget to set lock bolt for idle gear A and
lock pin for idle gear C.
7. Remove timing gear case.
8. Remove oil level gauge guide assembly.
9. Remove flywheel assembly.
CAUTION:
1) The flywheel heavy; be careful not to drop it.
2) Be careful no to let it slip because the hexagon
of the bolt is thin.10. Remove rear plate (for A/T) or flywheel housing (for
MT).
11. Remove retainer.
NOTE:
1) Be careful not to damage the oil seal; it can be
reused.
2) Inspect installation portion for distortion and flow on
the slinger; also inspect for flow on the oil seal lip.
3) If there is some flow oil seal/slinger, replace a set.
12. Remove bolts from thrust plate of balance shaft LH
then remove balance shaft.
13. Loosen crank case fixing bolts.
14. Use seal cutter to take off the liquid gasket.
Seal cutter: 5-8840-2153-0
15. Remove crank case assembly.
CAUTION:
Do not give shock to crank case for prevention take
off applied vibration insulation material on the
crank case.
1
2
3
012RW029
Legend
(1) Crank Case
(2) Oil Pan
(3) Drain Plug

6E±5 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
Conditions for Clearing the MIL/DTC 6E±159. . . . .
Diagnostic Aids 6E±159. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1562
(Flash DTC 35) System Voltage Too Low
at Cranking 6E±160. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E±160. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±160. . . . . . .
Conditions for Clearing the MIL/DTC 6E±160. . . . .
Diagnostic Aids 6E±160. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1587
(Flash DTC 25) Brake SW Malfunction 6E±161. . . .
Circuit Description 6E±161. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±161. . . . . . .
Conditions for Clearing the MIL/DTC 6E±161. . . . .
Diagnostic Aids 6E±161. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1588
(Flash DTC 25) Brake SW Malfunction 6E±163. . . .
Circuit Description 6E±163. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±163. . . . . . .
Conditions for Clearing the MIL/DTC 6E±163. . . . .
Diagnostic Aids 6E±163. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0601
(Flash DTC 55) ECM Checksum Error 6E±165. . . . .
Action Taken When the DTC Sets 6E±165. . . . . . .
Conditions for Clearing the MIL/DTC 6E±165. . . . .
Diagnostic Aids 6E±165. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0650
(Flash DTC 77) Check Engine Lam Circuit
Open/Short 6E±166. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E±166. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±166. . . . . . .
Conditions for Clearing the MIL/DTC 6E±166. . . . .
Diagnostic Aids 6E±166. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0654
(Flash DTC 27) Tachometer Circuit
Open/Short 6E±168. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E±168. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±168. . . . . . .
Conditions for Clearing the MIL/DTC 6E±168. . . . .
Diagnostic Aids 6E±168. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1655
(Flash DTC 17) Thermo Relay Circuit
Open/Short 6E±170. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E±170. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±170. . . . . . .
Conditions for Clearing the MIL/DTC 6E±170. . . . .
Diagnostic Aids 6E±170. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1657
(Flash DTC 76) ECM Main Relay Circuit
Open/Short 6E±172. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E±172. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±172. . . . . . .
Conditions for Clearing the MIL/DTC 6E±172. . . . .
Diagnostic Aids 6E±172. . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code (DTC) P1589
(Flash DTC 47) Transmission SW Circuit
Open/Short 6E±174. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E±174. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E±174. . . . . . .
Conditions for Clearing the MIL/DTC 6E±174. . . . .
Diagnostic Aids 6E±174. . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 6E±176. . . . . . . . . . . . . . . . . . . . .
Default Matrix Table 6E±199. . . . . . . . . . . . . . . . . . . . .
On±Vehicle Service Camshaft Position
(CMP) Sensor 6E±201. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E±201. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E±201. . . . . . . . . . . . . . . . . .
Installation Procedure 6E±201. . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor 6E±202. . . . . . . . .
Removal Procedure 6E±202. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±202. . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E±203.
Removal Procedure 6E±203. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±203. . . . . . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor 6E±203. . . . . . .
Removal Procedure 6E±203. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±204. . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor 6E±204.
Removal Procedure 6E±204. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±205. . . . . . . . . . . . . . . . . .
Oil Temperature (OT) Sensor 6E±205. . . . . . . . . . . . .
Removal Procedure 6E±205. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±206. . . . . . . . . . . . . . . . . .
Malfunction Indicator Lamp (MIL) 6E±206. . . . . . . . . .
Removal and Installation Procedure 6E±206. . . . . .
Engine Control Module (ECM) 6E±206. . . . . . . . . . . .
Service Precaution 6E±206. . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge (ESD) Damage 6E±206. . .
Removal Procedure 6E±207. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±208. . . . . . . . . . . . . . . . . .
EEPROM 6E±208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6E±208. . . . . . . . . . . . . . . . . . . .
Functional Check 6E±208. . . . . . . . . . . . . . . . . . . . . .
Intake Throttle Position (ITP) Sensor 6E±208. . . . . . .
Removal Procedure 6E±208. . . . . . . . . . . . . . . . . . . .
Function Check 6E±209. . . . . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±209. . . . . . . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) 6E±210. . . . . . . . . . . . .
Removal Procedure 6E±210. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E±210. . . . . . . . . . . . . . . . . .
Installation Procedure 6E±210. . . . . . . . . . . . . . . . . .
Air Cleaner/Air Filter 6E±211. . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E±211. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±211. . . . . . . . . . . . . . . . . .
Accel Position (AP) Sensor 6E±211. . . . . . . . . . . . . . .
Removal Procedure 6E±211. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E±212. . . . . . . . . . . . . . . . . .
Accelerator Pedal Replacement 6E±212. . . . . . . . . . .

6E±23 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
Abbreviations Charts
List of abbreviations which may be used in this section.
Abbreviations
TermAbbreviationsTerm
A/CAir ConditionerBLKBlack
A/TAutomatic TransmissionBLUBlue
ACCAccessoryBRNBrown
APAccel PositionGRNGreen
ASMAssemblyGRYGray
CKPCrank PositionLT BLULight Blue
CMPCam PositionLT GRNLight Green
DLCData Link ConnectorORNOrange
DTCDiagnosis Trouble CodePNKPink
DVMDigital Volt MeterREDRed
ECMEngine Control ModuleVIOViolet
ECTEngine Coolant TemperatureWHTWhite
EGRExhaust Gas RecircurationYELYellow
EVRVElectric Vacuum Regulating Valve
EXHExhaust
FTFuel Temperature
IATIntake Air Temperature
IGIgnition
ITPIntake Throttle Position
M/TManual Transmission
MAPManifold Absolute Pressure
MILMulfunction Indicator Lamp
OBDOn-Board Diagnostic
OTOil Temperature
QOSQuick on Start System
QWSQuick Warming-Up System
RPRail Pressure
RPCVRail Pressure Control Valve
SRSSupplemental Restraint System
STStart
SWSwitch
TEMPTemperature
TODTorque on Demand
VSSVehicle Speed Sensor
VSVVacuum Switching Valve
HEUIHydraulically Actuated Electronically Controlled Unit
InjectorInjector

6E±26
4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
Output Components:
Output components are diagnosed for proper response to
control module commands. Components where
functional monitoring is not feasible will be monitored for
circuit continuity and out-of-range values if applicable.
Output components to be monitored include, but are not
limited to, the following circuit:

EGR VSV

EGR EVRV

Electronic Transmission controls

Injector

Intake throttle

Glow plug

MIL control
Refer to ECM and Sensors in General Descriptions.
Passive and Active Diagnostic Tests
A passive test is a diagnostic test which simply monitors a
vehicle system or component. Conversely, an active test,
actually takes some sort of action when performing
diagnostic functions, often in response to a failed passive
test.
Intrusive Diagnostic Tests
This is any on-board test run by the Diagnostic
Management System which may have an effect on
vehicle performance or emission levels.
Warm-Up Cycle
A warm-up cycle means that engine at temperature must
reach a minimum of 70
C (160
F)
and rise at least 22
C
(40
F) over the course of a trip.
Freeze Frame
Freeze Frame is an element of the Diagnostic
Management System which stores various vehicle
information at the moment an emissions-related fault is
stored in memory and when the MIL is commanded on.
These data can help to identify the cause of a fault. Refer
to
Storing And Erasing Freeze Fame Data for more
detailed information.
Failure Records
Failure Records data is an enhancement of the OBD
Freeze Frame feature. Failure Records store the same
vehicle information as does Freeze Frame, but it will store
that information for any fault which is stored in on-board
memory, while Freeze Frame stores information only for
emission-related faults that command the MIL on.
Common OBD Terms
Diagnostic
When used as a noun, the word diagnostic refers to any
on-board test run by the vehicle's Diagnostic
Management System. A diagnostic is simply a test run on
a system or component to determine if the system or
component is operating according to specification. There
are many diagnostics, shown in the following list:

EGR

engine speed

vehicle speed

ECT
MAP

VSV

IAT

ITP

AP

FT (Fuel Temp)

RP (Rail Pressure)

OT (Oil Temp)

EGR EVRV

Idle SW

Brake SW
The Diagnostic Executive
The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:

Commanding the MIL (ªCheck Engineº lamp) on and
off

DTC logging and clearing

Freeze Frame data for the first emission related DTC
recorded

Current status information on each diagnostic
Diagnostic Information
The diagnostic charts and functional checks are designed
to locate a faulty circuit or component through a process
of logical decisions. The charts are prepared with the
requirement that the vehicle functioned correctly at the
time of assembly and that there are not multiple faults
present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented by
the diagnostic procedures contained in this manual. The
language of communicating the source of the malfunction
is a system of diagnostic trouble codes. When a
malfunction is detected by the control module, a
diagnostic trouble code is set and the Malfunction
Indicator Lamp (MIL) (ªCheck Engineº lamp) is
illuminated.
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) looks the same as
the MIL you are already familiar with ªCheck Engineº
lamp.
Basically, the MIL is turned on when the ECM detects a
DTC that will impact the vehicle emissions.

When the MIL remains ªONº while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a Powertrain
On-Board Diagnostic (OBD) System Check must be
performed. The procedures for these checks are
given in On-Board Diagnostic (OBD) System Check.
These checks will expose faults which may not be
detected if other diagnostics are performed first.
DTC Types
Characteristic of Code