Isuzu Trooper (1998-2002 year). 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