Isuzu Trooper (1998-2002 year). Manual - part 548

6J–2

INDUCTION

Air Cleaner Element

Removal

1. Remove positive ventilation hose from connector(1).
2. Remove intake air temperature sensor(2).
3. Remove air flow sensor(3).
4. Remove air cleaner duct cover(4).
5. Remove air cleaner element(5).

130RW003

Inspection

Check the air cleaner element for damage or dust
clogging. Replace if it is damaged, or clean if it is clogged.

Cleaning Method

Tap the air cleaner element gently so as not to damage
the paper element, or clean the element by blowing with
compressed air of about 490 kPa (71 psi) from the clean
side if it is extremely dirty.

130RW002

Installation

1. Install air cleaner element(5).
2. Attach the air cleaner duct cover (4) to the body

completely, then clamp it with the clip.

3. Install mass air flow sensor(3).
4. Install air temperature sensor(2).
5. Connect positive crankcase ventilation hose to

connector(1).

130RW003

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–38

Cylinder 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

SECTION

6A – 2 ENGINE MECHANICAL

GENERAL DESCRIPTION 

Cylinder Head Gasket

The cylinder head gasket is laminated steel sheets.
Three grades of the gasket according to the measured
piston head projection from the cylinder block are
provided to give the engine a minimum compression
ratio fluctuation.

Tightening Method for

Special Bolt

The cylinder head fixing bolts, flywheel bolts and
connecting rod cap fixing bolts are tightened by the
angular Tightening Method.

Piston

Auto-thermatic pistons having steel struts with a 0.4
mm offset from the piston pin center line, are applied to
reduce thermal expansion and resulting engine noise
when the engine is cold.

Bearings

The crankshaft bearings and connecting rod bearings
are of aluminum having a high bearing surface.
These bearings are especially sensitive to foreign
material such as metal scraps. So, it is very important
that the oil ports and other related surfaces are kept
clean and free of foreign material.
Crankshaft bearings are selected for optimum bearing
and journal clearance which reduces vebration and
noise.

For General Export

For Europe

F06R200004

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. 58°

Exhaust valves

open at:

B.B.D.C. 57°

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.