1998 ISUZU TROOPER oil filter

00 Ð 48 SERVICE INFORMATION
SPECIAL TOOLS (CONT.1)
5-8840-0145-0
5-8522-0024-0
5-8840-0266-0
5-8840-9016-0
5-8840-2038-0
5-8840-2061-0
ILLUSTRATION
TOOL NAME TOOL NO.
Measuring Device
Crankshaft Timing Gear Installer
Angle Gauge
Injection Nozzle Tester
Bearing Replacer
Crankshaft Front Oil Seal Installer
5-8840-2032-0
5-8840-0259-0
5-8840-0253-0 (J-22700)Engine Hanger
Nozzle Holder Wrench
Fuel Filter Wrench
5-8840-2360-0 Crankshaft Rear Oil Seal Remover
5-8840-2359-0 Crankshaft Rear Oil Seal Installer

4JG2-NA/4JG2-TURBO ENGINE 6A2 Ð 33
OIL FILTER CARTRIDGE
REMOVAL
·Place a receptacle beneath the oil filter to contain the
drained oil.
·Remove the oil filter cartridge using filter wrench.
Filter wrench: 5-8840-0200-0
INSTALLATION
·Lightly oil the o-ring of oil filter cartridge.
·Turn in the new oil filter cartridge by hand until the
sealing face is fiffted again the o-ring.
·Use the filter wrench to turn in the oil filter and
additional one and 1á1/8 turns.
·Start the engine and check for oil leakage from oil filter.

ENGINE COOLING 6B Ð 3
The cooling system is a pressurized coolant forced
circulation type which consists of water pump, thermostat
cooling fan, radiator and other components. The
circulating coolant cools the lubricating oil in the oil filter
and turbocharger.
WATER PUMP
The coolant pump is a centrifugal impeller type and is
driven by V type drive belt.
THERMOSTAT
The thermostat is a wax pellet type with a jiggle valve and
is installed in the thermostat housing.
RADIATOR
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of coolant, the radiator is fitted
with a cap in which the valve is operated under the
pressure.

6C Ð 8 FUEL SYSTEM
FUEL FILTER CARTRIGE
DISASSEMBLY
·Drain fuel completely from the fuel filter.
·Protect the filter body with cloth and lightly grip with
a vise.
·Remove sedimentor center.
·Remove the cartridge using a filter wrench.
Filter wrench: 5-8840-0253-0(J-22700)
REASSEMBLY
·Install the sedimentor center.
Clean the cartridge mounting surface of filter body
so that the cartridge can be securely.
Apply engine oil thinly to new cartridge o-ring.
·To facilitate bleeding, fill the new cartridge with
light oil.
·Tighten the cartridge until o-ring comes in contact
with the sealing, taking care not to spill the light
oil.
·Retighten 1/3~2/3 using a filter wrench.
Filter wrench: 5-8840-0253-0(J-22700)
Bleeding
·Operate priming pump to send the air in the fuel
system to the injection pump.
·Loosen injection pump bleeding plug, and operate
the priming pump until no bubble is made.
·Tighten the bleeding plug.
·Start the engine, and if it is not started in 10 sec-
onds or less, repeat the bleeding steps.
·Make sure of no fuel leakage, and tighten the
priming pump.
Draining
·When the water in the sedimentor reaches the
specified volume, warning light is actuated.
In this case, follow the draining steps below.
·Set a vinyI hose over the drain plug.
·Loosen the drain plug.
·To drain the water, operate the priming pump
several times.
·After draining, tighten the drain plug.
·Operate the priming pump several times to check
for fuel leakage.
·Check and see the warning light is off.

ENGINE MECHANICAL 6A – 1
ENGINE
ENGINE MECHANICAL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . 6A–2
Service Information . . . . . . . . . . . . . . . . . . . . 6A–3
Service Standard . . . . . . . . . . . . . . . . . . . . . . 6A–6
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–9
Tightening Torque . . . . . . . . . . . . . . . . . . . . . 6A–14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . 6A–28
Engine Mount (RH) . . . . . . . . . . . . . . . . . . . . 6A–30
Engine Mount (LH). . . . . . . . . . . . . . . . . . . . . 6A–31
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . 6A–33
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . 6A–36
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 6A–38Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 6A–41
Cylinder Head Gasket . . . . . . . . . . . . . . . . . . 6A–43
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–47
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–52
Valve Stem Seal, Valve Spring and Adjuster . . 6A–60
Valve Clearance Adjustment. . . . . . . . . . . . . . 6A–67
Oil Rail and Injector . . . . . . . . . . . . . . . . . . . . 6A–69
Crank Case . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–72
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–74
Piston and Connecting Rod . . . . . . . . . . . . . . 6A–84
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . 6A–92
Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . 6A–98
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . 6A–99
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–99

ENGINE MECHANICAL 6A – 3
SERVICE INFORMATION
MAIN DATA AND SPECIFICATION
Engine type Diesel, four cycle water cooled inline
Camshaft type DOHC
Number of cylinders 4
Bore x stroke (mm) 95.4 x 104.9
Total piston displacement (cc) 2999
Compression ratio (to 1) 19.0
For Europe : 18.5
Engine weight (dry) N (kg/lb) 2492 (254/560) (A/T)
For Europe : 2422 (247/545) (A/T)
2649 (270/593) (M/T)
For Europe : 2697 (275/606) (M/T)
Engine idling speed (Reference) RPM 720
Compression pressure kpa (kg/cm
2/psi)-rpm 3040 (31/441)-200
Firing order 1–3–4–2
VALVE SYSTEM
Intake valves open at: B.T.D.C. 3°
close at: A.B.D.C. 57.6°
Exhaust valves open at: B.B.D.C. 56.5°
close at: A.T.D.C. 5°
Valve clearance (at cold) mm (in)
intake: 0.15 (0.006)
exhaust: 0.25 (0.01)
Oil filter Full flow and bypass combined type
Oil capacity (Original factory fill or rebuilt engine) 9.0 liters (7.9 US quarts)
Oil capacity (Service change)
with filter change 6.0 liters (6.3 US quarts)
without filter change 5.0 liters (5.3 US quarts)
Oil cooler Water cooled type
Inter cooler Air cooled type
Turbocharger method
Control method Wastegate control
Lubrication Pressurized control
Cooling method Coolant cooled
Crankshaft
As tufftriding (Nitrizing treatment) is applied to increase
crankshaft strength, crankpins and journals should not
be reground.
Piston Cooling
An oiling jet device for piston cooling is provided in the
lubricating oil circuit from the cylinder block oil gallery
via a check valve.
Take care not to damage any oiling jet when removing
and installing piston and connecting assembly.
Fuel Injection System
The injection system is oil rail type.
Quick On Start 4 System
QOS4 preheating system which features a quick-on
glow plug with thermometer control of the glowing time
and the afterglow time function, is applied.

ENGINE MECHANICAL 6A – 9
SERVICING
Servicing refers to general maintenance procedures to
be performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand
side of the cylinder body.
AIR CLEANER
Oil Wetted (Viscous) Type Paper Element.
The air cleaner has an oil wetted paper element. No
servicing is required until the replacement interval is
reached.
Never attempt to clean the element, no matter how dirty
it may appear. The element is designed to provide
normal filtering efficiency until it becomes due for
replacement.
Refer to the Item “Service and Maintenance” in the
Owner’s and Driver’s Manual for general service
information.
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Loosen the drain plug to drain the engine oil.
2. Wait a few minutes and then retighten the drain
plug.
3. Loosen the used oil filter (2) by turning it counter-
clockwise with the filter wrench.
4. Clean the oil filer gasket fitting face.
This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the O-ring.
6. Turn the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn the filter additional one
and 1/4 turns.
Filter Wrench: 5-5540-0203-0
012RW115
012RW062
For Europe1
2
050R200001

6A – 10 ENGINE MECHANICAL
8. Check the engine oil level and replenish to the
specified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel filter
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
Filter Wrench : 5-8840-0203-0
2. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn the fuel filter with a filter wrench 2/3 of a turn
until sealed.
Filter Wrench: 5-8840-0203-0Legend
(1) Priming pump
6. Operate the priming pump until the air is discharged
completely from fuel system.
NOTE: The use of an Isuzu genuine fuel filter is
strongly recommended.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator
reserve tank as necessary.
If the coolant level falls below the “‘MIN” line, carefully
check the cooling system for leakage. Then add
enough coolant to bring the level up to the “MAX” line.
NOTE: Do not overfill the reserve tank.
012RW112
012RW078
1
012RW111
012RW080