Isuzu Trooper (1998-2002 year). Service manual — part 652
6J – 8 INDUCTION
7. Water inlet pipe.
1) Install water inlet pipe with a new gasket, tighten
bolts to the specified torque.
Torque: 9 N·m (0.9 kg·m / 78 lb in)
8. Install intercooler assembly.
Refer to “Intercooler” in this manual.
9. Install air cleaner cover with air duct.
10. Fill engine coolant to full level.
11. Install battery and connect battery cable.
For Europe
025R200007
INDUCTION 6J – 9
INTERCOOLER
REMOVAL
1. Disconnect battery ground cable.
2. Remove air cleaner cover with air duct.
3. Remove intercooler cover.
4. Intercooler assembly.
1) Remove rubber hose from intercooler outlet
side.
2) Remove rubber hose from intercooler inlet side.
3) Remove four fixing bolts and remove intercooler
assembly.
INSPECTION AND REPAIR
1. Visual check for clogs in the fins.
2. Check for brokens on the tube.
3. If any problem on the intercooler is observed during
inspection, clean or replace the intercooler.
INSTALLATION
1. Intercooler assembly.
1) Connect outlet hose to intake manifold.
Tighten hose clamp to the specified torque.
Torque: 4 N·m (0.4 kg·m / 35 lb in)
2) Connect inlet hose to the turbocharger outlet
side.
Tighten hose clamp to the specified torque.
Torque: 4 N·m (0.4 kg·m / 35 lb in)
3) Install intercooler assembly, 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 battery ground cable.
For Europe
2
3
3
1
Legend
(1)
Air Cleaner Cover and Air Duct
(2)
Intercooler Cover
(3)
Intercooler Assembly
135R200003
6J – 10 INDUCTION
REMOVAL
1. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
2. Remove harness connector from motor and ITP
sensor.
3. Loosen the two fixing nuts and remove the throttle
valve assembly.
Legend
(1) Motor
(2) Intake Throttle Valve
(3) ITP sensor
INSPECTION AND REPAIR
1. Check for catching somwhere on the throttle valve.
2. If some problem is discovered during inspection on
the throttle valve, the throttle valve must replace.
INSTALLATION
1. Put gasket on the intake manifold and install throttle
valve.
2. Tighten nuts to the specified torque.
Torque: 20 N·m (2.0 kg·m / 14 lb ft)
3. Reconnect harness connector to motor and
ITPsensor.
4. Install intercooler assembly.
1
2
3
025RW032
INTAKE THROTTLE VALVE
INDUCTION 6J – 11
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and remove water hose from
thermostat housing
2. Remove intercooler assembly.
3. Remove bracket fixing bolt of oil level gauge guide
tube.
4. Remove PCV hose.
5. Remove hoses from EGR valve, EGR vacuum
sensor and outlet of heater unit.
6. Disconnect harness connector from MAP sensor,
EGR vacuum sensor, ETC sensor, Water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove two way check valve.
9. Remove fuel pipe.
10. Remove fixing bolts and nuts of intake manifold,
remove intake manifold assembly.
Legend
(1) Intake manifold
(2) Fixing portion of throttle valve
(3) EGR passage
(4) EGR valve
For Europe
2
1
3
3
1
4
2
Legend
(1)
Intake Manifold
(2)
Throttle Valve Assembly
(3)
EGR Valve
(4)
Gasket
025R200005
3
1
2
4
025RW031
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