Isuzu Trooper (1998-2002 year). Manual - part 649

6G – 6 ENGINE LUBRICATION

OIL COOLER ASSEMBLY

REMOVAL

1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove front exhaust pipe.
4. Remove heat protector.
5. Remove exhaust valve assembly.
6. Oil cooler assembly.

1) Remove water hose from water inlet and outlet

side.

2) Cloth should be put under the oil cooler to

prevent oil from flowing out.

3) Loosen fixing bolt then remove oil cooler

assembly.

Legend 

(1) Oil cooler assembly
(2) Oil filter assembly

INSPECTION AND REPAIR

1. Inspect for corrosion, wear, and breaks on the oil

cooler core.

2. If a problem is found on the oil cooler core, the oil

cooler assembly must be replaced.

INSTALLATION

1. Oil cooler assembly

1) Tighten oil cooler fixing bolt to the specified

torque and install water hoses.

Torque: 29 N·m (3.0 kg·m / 22 lb ft)

2. Install exhaust valve assembly to turbocharger

assembly and tighten to the specified torque.

Torque: 27 N·m (2.8 kg·m / 20 lb ft)

3. Install front exhaust pipe to the exhaust valve.

Torque: 

67 N·m (6.8 kg·.m / 49 lb ft) 
(At exhaust valve side)

43 N·m (4.4 kg·m / 32 lb ft) 
(At center exhaust pipe side)

4. Install heater protector.
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and carefully check for leakage of oil

and coolant.

OIL COOLER SPECIFICATIONS

Cooling method

Water cooled 

Multi plate type

Heat exchange Area

0.323 m

2

Heat exchange capacity

>11,300 kcl/h

Relief Valve opening 

245 Kpa (2.5 kg/cm

2

/36 psi)

pressure

OIL FILTER

REMOVAL

1. Put container under the oil filter to prevent oil from

the oil filter from flowing out.

2. Use filter wrench to remove oil filter.

Filter wrench: 5-8840-0203-0

INSTALLATION

1. Apply engine oil thinly to oil filter O-ring.
2. Tighten oil filter by hand until O-ring comes in

contact with the sealing surface.

3. Use filter wrench to tighten oil filter one turn and 1/8

turn.

4. Start engine and carefully check for oil leakage from

oil filter.

SUB OIL FILTER 

The sub oil filter requires no servicing until the
replacement interval is reached.
The element is designed to provide special filtering
efficiency until it becomes due for replacement.
It is recommended to check and replace the sub oil filter
when the engine is being overhauled or if it is broken
inside the engine.

For Europe

1

2

050R200001

ENGINE SPEED CONTROL 6H – 1

ENGINE SPEED CONTROL

CONTENTS 

General Description . . . . . . . . . . . . . . . . . . 

6H–2

Accelerator Pedal . . . . . . . . . . . . . . . . . . . . 

6H–3

SECTION

6H – 2 ENGINE SPEED CONTROL

GENERAL DESCRIPTION 

2

1

101R200006

Engine control has been changed from the control
cable system to an electronically controlled TP (Throttle
Position) sensor.
The TP sensor is a potentiometer (Variable resistance)
type and installed to the accelerator pedal bracket.
A voltage of 5 V is always applied from the ECM
(Electronic Control Module) to the TP sensor so that the
operating angle of the accelerator pedal can be
detected from a change in voltage.
Further, this sensor is equipped with an accelerator
switch which sends signals to the ECM when the
accelerator pedal is stepped on. 
This switch remains on and turns off only when the
accelerator pedal is stepped on.

All vehicles have no throttle cable, and therefore, a
return spring is provided on the accelerator pedal and a
return cable assembly having the sliding resistance of a
cable is used to give the pedal a feeling.
To meet the newly adopted electronic control system,
the idling control button has been dropped.

Legend

(1)

Accerator Position Sensor

(2)

Return Cable

ENGINE SPEED CONTROL 6H – 3

REMOVAL

1. Remove harness connector from accel position

(AP) sensor.

2. Remove accelerator pedal assembly from chassis.

INSPECTION AND REPAIR

1. Check moving condition of accelerator pedal, if not

smooth working, apply oil to the pivot etc.

2. Check tightening condition of accel position (AP)

sensor, if not completely tightened, it should be
tightened additionally.

INSTALLATION

1. Install accelerator pedal assembly to chassis.
2. Connect harness connector to accel position (AP)

sensor.

ACCELERATOR PEDAL