Isuzu Trooper (1998-2002 year). Service manual — part 556
6A – 32 ENGINE MECHANICAL
INTERCOOLER
REMOVAL
1. Disconnect the battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler cover.
4. Remove intercooler assembly.
1) Remove rubber hose from between intercooler
outlet and intake manifold inlet.
2) Remove rubber hose from between
turbocharger outlet and intercooler inlet.
3) Remove intercooler assembly fixing bolts from
the bracket, remove intercooler assembly.
INSTALLATION
1. Intercooler assembly
1) Connect outlet hose to intake manifold.
Torque : 4 N·m (0.4 kg·m/35 lb in)
2) Connect inlet hose from turbocharger to
intercooler.
Torque : 4 N·m (0.4 kg·m/35 lb in)
3) Install intercooler and tighten fixing bolts to the
specified torque.
Torque : 20 N·m (2.0 kg·m/14 lb ft)
2. Install intercooler cover.
3. Install air cleaner cover and air duct.
4. Connect the battery ground cable.
For Europe
2
3
3
1
135R200003
Legend
(1)
Air Cleaner Cover & Air Duct
(2)
Intercooler Cover
(3)
Intercooler Assembly
ENGINE MECHANICAL 6A – 33
CYLINDER HEAD COVER
REMOVAL
1. Disconnect battery ground cable.
2. Remove clip, remove air cleaner cover and air duct.
3. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
4. Remove PCV hose.
5. Remove bolts which fix noise insulator cover then
remove noise insulator cover and insulator.
6. Remove high pressure oil pipe at cylinder head
side.
Take care when removing the injector oil pipe,
because sometimes, during removal, your hand
can be injured by the remaining high pressure oil.
INSTALLATION
1. Cylinder head cover.
1) Install the cylinder head cover gasket to cylinder
head cover.
2) The gasket must be set perfectly with no loose
areas.
3) Apply liquid gasket (TB1207B or equivalent) to
the rubber seal of the camshaft end, injector
harness gasket area and No. 1 camshaft
bracket.
4) Tighten cylinder head cover fixing bolts to the
specified torque.
Torque : 9 N·m (0.9 kg·m/78 lb in)
2. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil rail filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.
3. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 78 N·m (8.0 kg·m/58 lb ft)
1
7
2
3
4
5
6
010R200006
Legend
(1)
Noise Insulator Cover
(2)
Insulator
(3)
Bolt
(4)
Oil Seal
(5)
Gasket
(6)
Cylinder Head Cover
(7)
Bolt
3~5
2~3
2~3
3~5
3~5
1~2
012RW119
6A – 34 ENGINE MECHANICAL
NOTE: Do not scratch the oil seal on the cylinder head
during installation of the high pressure oil pipe.
4. Install the noise insulator and its cover on the
cylinder head cover.
NOTE: Do not catch the injector harness with the noise
insulator cover.
5. Connect the PCV hose.
6. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
7. Install air cleaner cover and air duct.
8. Connect battery ground cable.
ENGINE MECHANICAL 6A – 35
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and disconnect water hose
from thermostat hosing.
2. Remove intercooler assembly
Refer to “Intercooler” in this manual.
3. Remove bracket bolt of oil level gauge guide tube.
4. Remove PCV Hose.
5. Remove hoses from EGR, EGR vacuum sensor
and inlet/outlet of heater.
6. Disconnect harness connector form MAP sensor,
EGR vacuum sensor, ETC sensor, water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove the two way valve.
9. Remove fuel pipe from between intake manifold
and high pressure oil pump.
10. Remove fixing bolts and nuts on the intake
manifold, then remove the intake manifold
assembly.
INSTALLATION
1. Install the intake manifold, tighten bolts and nuts to
the specified torque.
Torque : 20 N·m (2.0 kg·m/14 lb ft) for bolt and nut
2. Install the fuel pipe and tighten to the specified
torque.
Torque :
M16 bolt (apply engine oil) 4 N·m (0.4 kg·m/35
lb in)
Cap nut (M10) 13N·m (1.3 kg·m/113 lb in)
Fuel pipe (M10 apply engine oil) 14 N·m (1.4
kg·m/122 lb in)
3. Install two way valve.
Torque : 20 N·m (2.0 kg·m/14 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.
5. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 78 N·m (8.0 kg·m/58 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water temperature
unit, IAT sensor and EVRV.
7. Connect the hoses to EGR valve, EGR vacuum
sensor, and water inlet/outlet pipe for heater.
8. Connect PCV hose.
9. Install the oil level gauge guide tube and tighten
bracket bolt.
10. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
11. Connect the hose to the thermostat housing and fill
with engine coolant.
For Europe
2
1
3
3
1
4
2
025R200005
Legend
(1)
Intake Manifold
(2)
Throttle Valve Assembly
(3)
EGR Valve
(4)
Gasket
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