1998 ISUZU TROOPER timing

0BÐ2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
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610
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1215
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1820
12
2425
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3030
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3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
GASOLINE ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
* Timing belt
Spark plugs (For leaded fuel use)
Spark plugs (For unleaded fuel use)
Exhaust system
Radiator coolant concentration
Cooling system for water leakage
All hoses and pipes in engine compartment
for clog or damage
Fuel filter
Fuel leakage
Fuel tank
* Air cleaner element
Pre air cleaner
Engine drive belt
Valve clearance
O
2 Sensor (For leaded fuel use)
O
2 Sensor (For unleaded fuel use)-
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(Replace every 165,000 km or 100,000 miles)
(Replace every 165,000 km or 100,000 miles)
(Check and adjust if necessary every 100,000 km or 60,000 miles)
(Replace every 150,000 km or 90,000 miles)
CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid leakage
*
(1)Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
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Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)
FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
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ATATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
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(1): Adjust or change automatic transmission fluid.
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”.

0BÐ4 MAINTENANCE AND LUBRICATION
DIESEL ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
3
610
6
1215
9
1820
12
2425
15
3030
18
3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
DIESEL ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
Idling speed and acceleration
Fan belt tension and damage
Timing belt
Exhaust system
All hoses and pipes in engine compartment
for clog or damage
Valve clearance
* Air cleaner element
Fuel filter
Radiator coolant concentration
Cooling system for water leakage-
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NOTE: In the 4JXI-TC diesel engine, there is provided sub (2nd) oil filter for fuel injection at the upper part of crank case on the left
side of the engine. This oil filter maintenance-free and does not need a periodic replacement. See reverse side the (back)
cover for installation location of the sub (2nd) oil filter.(Replace every 200,000 km or 125,000 miles)
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”. CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
* Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
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ATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
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0BÐ6 MAINTENANCE AND LUBRICATION
Item IntervalCondition
ABCD A+D
Engine oil G : Change every 5,000 km (3,000 miles)
D : Change every 5,000 km (3,000 miles) ll
Engine oil filter G : Replace every 10,000 km (6,000 miles)
D : Replace every 5,000 km (3,000 miles) ll
Air cleaner element G : Replace every 20,000 km (12,000 miles)
D : Replace every 40,000 km (25,000 miles)l
Power steering fluid Replace every 50,000 km (30,000 miles)ll
Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)l
Universal joints and sleeves Inspect for wear and lubricate every 7,500 km (4,500 miles)ll
Transmission with MT Change every 20,000 km (12,000 miles)
transfer case oil after changing at initial 10,000 km (6,000 miles)l
Transmission :
AT
Change every 32,000 km (20,000 miles) lll l
Transfer:
TF Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)l
Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 5,000 km (3,000 miles) l
Disc brake pads and discs Inspect every 5,000 km (3,000 miles)lll
Timing belt G : Replace every 120,000 km (75,000 miles)ll
EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE
Explanations of the services listed in the proceeding
Maintenance Scheduled are presented in ÒService
InformationÓ section of each manual.Replace all questionable parts and note any
necessary repairs as you perform these
maintenance procedures.
MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS
Severe driving conditions
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads

1BÐ74 AIR CONDITIONING
FUNCTIONS AND FEATURES
¥ Automatic interior temperature control
This function enables to maintain the interior temperature at the level specified from the temperature
control switch despite of changes in factors such as vehicle speeds, outside air temperature and number
of passengers.
¥ Maximum cooling and heating function
You can select FC (Full cool, namely maximum cooling temperature) or FH (Full heat, maximum heating
temperature) from the temperature control lever.
¥ Automatic air flow control
Air flow is automatically and consecutively fine tuned according to the specified interior temperature and
changes in aperture of the heater unit mix door.
¥ Mode (blow port) control
This function automatically selects either one of the VENT, BI-LEVEL, FOOT or DEP mode for the blow
port according to changes of temperature on the blow port. Using the mode switch allows you to select a
desired blow port manually.
¥ Intake (switching between the fresh air intake and circulation of interior air) control
The intake (switching between fresh air intake and circulation of interior air) mode automatically selects
either FRESH (fresh air intake), MIX or RECIRC (interior air circulation) according to changes of the blow
port temperature. Using the intake switch allows you to select a desired intake port manually (in the
manual operation, FRESH and RECIRC modes alone are available). Pressing the DEF (defrost) mode
switch selects the FRESH (fresh air intake).
¥ Cooler start-up timing control
This function is used for maintaining the air flow at "LOW" level until the evaporator is sufficiently cooled
down. It is intended to prevent a large volume of hot air being blowing into inside of a vehicle when the
cooler is turned on in hot summer season.
¥ Heater start-up timing control
This function is used for maintained the air flow at "LOW" level and also for maintaining the defrost
mode until temperature of coolant in the heater core is sufficiently heated. It is intended to prevent a
large volume of cool air being blown into inside of a vehicle when the heater is turned on in cold winter
season.
¥ Solar radiation quantity offset control
The photodiode on the solar radiation sensor determines solar radiation quantity accurately to offset
interior temperature quickly.
¥ Switch position storing function
This function is used for storing switch positions being selected in the immediately preceding operation,
namely the last time the ignition has been turned off. It simplifies the setup procedures when restarting
the system.
¥ Self-diagnosis function
The self-diagnosis function turned on from the panel switch makes your troubleshooting easier (for detail
of this function, refer to the section titled "Self-Diagnosis").

1BÐ88 AIR CONDITIONING
OVERVIEW OF AUTOMATIC CONTROL OF
FULL AUTOMATIC AIR CONDITIONER
The full automatic heater and air conditioner on this
vehicle has the following features:
¥ Interior temperature control.
¥ Air flow control.
¥ Mode (blow port) control.
¥ Intake (switching between fresh air and interior
air) control.
¥ Heater start timing control.
¥ Cooler start timing control.
¥ Evaporator anti-freeze control.
1. Interior Temperature Control
The automatic heater/air conditioner control unit
operates on the setup temperature signal from
the temperature control switch and other sensor
signals to derive the total signal. Then, the
control unit compares this signal against the
signal from the potentiometer to determine
rotation direction of the mix actuator. The mix
actuator moves the air mix door to the aperture
specified by the total signal so that the specified
interior temperature is achieved.
If the compressor is turned off in the A/C (air
conditioning) mode, aperture of the air mix door
is offset according to the outside air temperature
or the specified interior temperature. This
function removes the difference in the blowing
temperature in this state and that of when the
compressor is turned on.
When FH or FC is selected for the setup
temperature, the air mix door is accordingly
fixed to the Full Heat or Full Cool mode.
When the VENT mode is selected, aperture of
the air mix door is controlled so that excessively
heated air may not be blown from the VENT
blow port.
0 50
140 104 68 32
Air mix door aperture
Full cool
Heater
side Restriction on the
aperture enabied
in the VENT modeAir conditioning
ON mode Full heatSet temperature
signal
Mix
actuator
Potentio
meter
Air mix door
In car sensor
Ambient sensor
Sun sensor
Control unitAir conditioning
switch
Set up temperature
signal
Air conditioning
OFF mode
Total signal Cooler
side
C01RY00011

AIR CONDITIONING 1BÐ91
6. Heating Start Timing Control
When the automatic heater/air conditioner is
started, heating is turned on under following
conditions.
·The detected temperature of thermo unit is
136¡F or less.
·The temperature setting signal and the total
signal by each sensor meet the condition of
heating.
When the detected temperature by the coolant
temperature sensor is 136¡F or less the blower
fan motor is set to work at low speed and the
"DEF" mode is selected.
When the detected temperature by the coolant
temperature sensor is 77¡F or more, the blow
mode changes automatic control. And the
blower fan speed is controlled to be lineally up
from "LO" to "MAX HI".7. Cooling Start Timing Control
When the automatic heater/air conditioner is
started, cooling is turned on under following
conditions.
·The in car sensor is 86¡F or more.
·The temperature setting signal and the signals
from each sensor meet the specified condition.
The blower fan speed is set to "LO" for
maximum 7 seconds when cooling start
conditions meet, and then, is controlled to be
lineally up to "MAX HI" by 5.32%/S.
Ignition swich
"ON"
Time
Blower voltage to turn
on the cooling
7 SEC maximum3 SEC
100%
(MAX HI)
33.5%
(LO)5.32%/S
C06RY00001
33.5%
(LO)
2.63%/S
Mode
DEF
Auto
Mode
100%
(MAX HI)
Ignition
switch "ON"
Thermo Unit 58¡C(Gasoline)
52¡C(Diesel) Time
840RY00009

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.