Kansas City, Missouri World Headquarters Web Auto Repair Database (WARD)

Education Division: Advanced Technology Career University (ATCU)
(Connecting Visions of Goals For The Future)

Advance Technology Career University U.S.A. Affiliates in Education
Tech Craftsman Career Building Trade School (TCCBTS)
Global Education Career Development, 501 (c) (3) Also Known As (GECD)

INDEPENDENT COMMERCIAL BUSINESS DIVISION: See ASSEMBLAGE OF RELATED SERVICES

In order to offer Tech Craftsman Career Building Trade School's interns/apprentices more than just going to work, becasue that's what TCCBTS is all about, 24 months, working 5 days a week and 8 hours each one of those 5 day weeks, yes, its a school but learning as if it was a job.

TCCBTS's goal is to reward our first-year interns/apprentices by expending their experiences so they can show off their skill while still going to school.

How? Easy we're going to create and develop several, Independent Commercial Businesses for the interns/apprentices to work before class or after class or both, and allowed to work on weekends and paid $15.00 dollars an hour. Now the interns/apprentices are not only earning real money, but learning on the job skill social by interacting with real customers asking for their experience and help.

INDEPENDENT COMMERCIAL BUSINESS DIVISION
Review: Assemblage of Auto Related Services to better under each individual commercial businesses. Read and Review ASSEMBLAGE OF RELATED SERVICES

Business Intellectural Concept Created by James E. Grow Library of Congress Copy(c) 2015-TXu-1-954607 Certificate of Registration

To return back to Tech Craftsman Career Building Trade School's Internship/Apprenticeship website click below: Tech Craftsman Career Building Trade SchoolInternship/Apprenticeship

Isuzu Trooper LS V6 3.5L Shop Manual
[Page 1]
ENGINE CONTENTS
Engine Mechanical
Engine Cooling
Engine Fuel
Engine Electrical
Ignition System
Starting and Charging System
Drive-ability and Emissions
Engine Exhaust
Engine Lubrication
Engine Speed Control System
Induction
ENGINE MECHANICAL CONTENTS
Service Precaution
General Description
Engine Diagnosis
Cylinder Head Cover L.H.
Removal
Installation
Common Chamber
Removal
Installation
Exhaust Manifold L.H.
Removal
Installation

Valve Spring, Oil Controller, Valve, Valve Guide
Valve Guide
Valve Spring, Oil Controller, Valve Guide and Associated Parts
Parts
Disassembly
Inspection and Repair
Re-assembly
Valve Clearance Adjustments
Camshaft
Camshaft and Associated Parts
Disassembly
Inspection and repair
Crankshaft
Crankshaft and Associated Parts
Disassembly
Inspection and repair
Reassembly
Piston and Connecting Rod
Piston, Connecting Rod and Associated Parts
Disassembly
Inspection and repair
Reassembly
Crankshaft and Main Bearings
Removal
Installation
Cylinder Block
Cylinder Block and Associated Parts
Dis-assembly
Inspection and repair
Re-assembly
Main Data and Specification
Special Tool
Rear Oil Seal
Removal
Installation
Engine Assembly
Removal
Installation
Cylinder Head and Associated Parts
Disassembly
Clean
Inspection and repair
Reassembly
Piston, Piston Ring and Connecting Rod
Removal
Installation
Valve Stem Oil Controller, Valve Spring and Valve Guide
Removal
Installation

[Page 2]
BATTERY
CONTITION POSSIBLE CAUSE CORRECTION
Headlights go out or dim considerable Battery run down or under charged
Terminal poorly connected
Starting motor coil circuit shorted
Starting motor defective
Recharge or replace battery
Clean battery posts and terminal and connect properly
Overhaul or replace
Overhaul or replace
IGNITION
2.Ignition Trouble----Starting Motor Turns Over But Engine Does Not Start
SPARK TEST
Disconnect an ignition coil from any spark plug. Connect the spark plug tester 5-0607-0, start the engine, and check if a spark is generated in the spark plug tester.
Before starting the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the part where insulation of the ignition coil is broken while the engine is running.
CONTITION POSSIBLE CUASE CORRECTION
Spark jumps across gap Spark plug defective
Ignition timing incorrect
Fuel not reaching fuel injector(s) or engine
Value timing incorrect
Engine lacks compression<br>
Clean, adjust spark gap or replace
Refer to Ignition System
Refer to item 3 (Trouble in fuel system)
Adjust
Refer to item 4 (Engine lacks compression)<br>
No sparking takes place Ignition coil disconnected or broken
Electronic ignition system with module
Poor connections in engine harness<br>
Power-Train Control Module cable disconnect or defective
Connect properly or replace
Replace
Correct
Correct or replace
3. [Page 3]
Trouble in Fuel System
CONDITION POSSIBLE CAUSE CORRECTION
Starting motor turns over and spark occurs
but engine does not start
Fuel tank empty
Water in fuel system
Fuel filter clogged
Fuel pipe clogged
Fuel pump defective
Fuel pump circuit open
Evaporative Emission Control System circuit clogged
Multi-port Fuel Injectiobn System Faulty
Fill
Clean
Replace Filter
Clean or replace
Replace
Correct or replace
Correct or replace
Refer to "Electronic Fuel Injection" section
4. Engine Lacks Compression
CONDITION POSSIBLE CAUSE CORRECTION
Engine Lacks Compression Spark plug loosely filter or spark plug gasket defective
Valve timing incorrect
Cylinder Head gasket defective
Valve incorrectly seated
Valve spring weakened or broken
Cylinder or piston rings worn
Piston ring sized
Tighten to specification torque or replace gasket
Adjust
Replace gasket
Lap valve
Replace valve and valve guide

Overhaul engine
[Page 4]
ENGINE COMPRESSION TEST PROCEDURE
1. Start and run the engine until the engine reaches normal operation temperature
2. Turn the engine off
3. Remove all the spark plugs
4. Remove ignition coil fuse (15A) and disable the ignition system
5. Remove the fuel pump relay from the relay and fuse box
6. Engage the starter and check that the cranking speed is approximately 300 rpm
7. Install cylinder compression gauge into spark plug hole
8. With the throttle valve
9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary
LIMIT; 1000 kPa (145 psi)
Rough engine Idling or Engine Stalling
CONDITION POSSIBLE CAUSE
CORRECTION
Trouble in fuel injection system
Idle air control valve defective
Throttle shutting off incomplete
Fuel injector Circuit open or shorted
Fuel injector damaged
Fuel pump relay defective
Mass Airflow Sensor circuit open or poor connections
Mass Airflow Sensor defective
Manifold Absolute Pressure Sensor circuit open or poor connections
Engine Coolant Temperature Sensor circuit open or poor connection
Intake Air Temperature Sensor circuit open or poor connection
Intake Air Temperature Sensor defective
Knock Sensor (KS) cable broken or poor connections
Knock Sensor defective
Vehicle Speed Sensor circuit open or shorted
Vehicle Speed Sensor defective
Replace
Correct or replace
Correct or replace
Replace
Correct or replace
Correct or replace
Replace
Correct or replace
Correct or replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
[Page 5]
Emission Control
Trouble in Emission Control System
Power-Train Control Module Defective
Exhaust Gas Recirculation Valve circuit open or poor connections
Exhaust Gas Recirculation valve faulty
Canister Purge Valve circuit open or poor connections
Canister Purge Valve defective
Evaporative Emission Canister Purge Control Valve defective
Trouble in ignition system
Replace
Correct or replace
Replace
Correct or rteplace
Replace
Replace
Refer to "Hard Start"
CONDITION POSSIBLE CAUSE
CORRECTIONS
Others Engine lacks compression
Valve incorrect seated
Air Cleaner Filter clogged
Valve timing incorrect
Idle Air Control valve broken
Fast idle Solenoid defective
Positive Crankcase Ventilation Valve defective or clogged
Refer to "Hard Start"
Lap valve
Replace filter element
Readjust
Replace
Replace
Replace


Rough Engine Running
CONDITION POSSIBLE CAUSE
CORRECTIONS
Engine Misfiring Periodically
Ignition coil layer shorted
Spark plug fouling
Spark plug(s) insulator nose leaking
Fuel injector(s) defective
Replace
Clean or install hotter type plug

Replace
Replace
[Page 6]
Engine Knock
Engine Knock Periodically
Spark plug running too hot
Power-Train Control Module Faulty
Install colder type spark plug
Replace
Engine Lacks Power
Spark plug fouled
Fuel injectors defective
Mass Airflow Sensor or Intake Airflow Sensor circuit defective
Manifold Absolute Pressure (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective
Engine Coolant Temperature Sensor or Engine Temperature Sensor circuit defective
Power-Train Control Module faulty
Intake Air Temperature Sensor or Intake Air Temperature Sensor circuit defective
Throttle Position Sensor or Throttle Position Sensor circuit defective
Knock Sensor or Knock Sensor circuit defective
knock Sensor Module or Knock Sensor Module circuit defective


Clean
Replace
Correct or replace
Correct or replace
Correct or replace
Replace
Correct or replace
Correct or replace
Correct or replace
Correct or replace

CONDITION POSSIBLE CAUSE
CORRECTION
Hesitation on Acceleration
Throttle Position Sensor adjustment incorrect
Throttle Position Sensor circuit open or shorted
Excessive play in accelerator linkage
Mass Airflow Sensor circuit open or poor connections
Mass Airflow Sensor defective
Manifold Absolute Pressure (MAP) Sensor circuit open or shorted
MAP Sensor defective
Intake Air Temperature (IAT) Sensor circuit open or shorted
Knock Sensor (KS) Circuit open or shorted
Knock Sensor defective
Knock Sensor Module circuit open or shorted
Knock Sensor Module defective
Intake Air Temperature Sensor defective
Replace throttle valve assembly
Correct or replace
Adjust or replace
Correct or replace
Replace
Correct or replace
Replace
Correct of replace
Correct or replace
Replace
Correct or replace
Replace
[Page 7]
Hesitation
CONDITION POSSIBLE CAUSE CORRECTIONS
Hesitation at High Speed (Fuel pressure to low) Fuel tank strainer clogged
Fuel pipe clogged
Fuel filter clogged
Defective fuel pump system
Fuel Pressure Control Valve leaking
Clean or replace
Clean or replace
Replace
Check and replace
Replace
Hesitation at High Speeds (Fuel injector not working normally) Power supply or ground circuit for Multi-port Fuel injection Shorted or open
Fuel Injector defective
Cable of Multi-port Fuel Injection System circuit open or poor connections
Check and correct or replace
Replace
Correct or replace
CONTITION POSSIBLE CAUSE CORRECTIONS
Hesitations at High Speeds Power-Train Control Module defective
Throttle Position sensor cable broken o rpoor connections
Throttle Position Sensor defective
Engine Coolant Temperature Sensor circuit open or shorted
Engine Coolant Temperature Sensor defective
Mass Airflow Sensor circuit open or poor connections
Mass Airflow Sensor defective
MAP Sensor cable broken or poor connections
Mass Airflow Sensor defective
MAP Sensor cable broken or poor connections
MAP Sensor defective
IAT Sensor circuit open or poor connections
lAT Sensor defective
Knock Sensor circuit open or poor connections
Knock Sensor defective
Throttle valve not fully open
Air Cleaner Filter clogged
Power Supply voltage too low
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Check and correct
Replace filter element
[Page 8]
Hesitation
CONDITION POSSIBLE CAUSE CORRECTIONS
Hesitation at High Speed (Fuel pressure to low) Fuel tank strainer clogged
Fuel pipe clogged
Fuel filter clogged
Defective fuel pump system
Fuel Pressure Control Valve leaking
Clean or replace
Clean or replace
Replace
Check and replace
Replace
Hesitation at High Speeds (Fuel injector not working normally) Power supply or ground circuit for Multi-port Fuel injection Shorted or open
Fuel Injector defective
Cable of Multi-port Fuel Injection System circuit open or poor connections
Check and correct or replace
Replace
Correct or replace
[Page 9}
Hesitation at High Speeds
CONDITION POSSIBLE CAUSE CORRECTIONS
Trouble in Fuel System Fuel Pressure Control Valve not working normally
Fuel Injector clogged
Fuel pipe clogged
Fuel filter clogged or fouled
Fuel pump drive circuit not working normally
Fuel tank not sufficiently breathing due to Evaporative Emission Control System circuit
Water in fuel system
Inferior quality fuel in fuel system
Power-Train Control Module supplied poor voltage
Throttle Position Sensor cable broken or poor connections
Throttle Position Sensor defective
Mass Airflow Sensor not working normally
Manifold Absolute Pressure Sensor not working normally
Intake Air Temperature Sensor not working normally
Engine Coolant Temperature Sensor circuit open or shorted
Engine Coolant Temperature Sensor defective
Power-Train Control Module defective
Replace
Clean or replace
Clean
Replace
Correct or replace
Clean or replace
Clean
Use fuel of specified octane rating
Correct circuit
Correct or replace
Replace
Replace
Replace
Replace
Correct or replace
Replace
Replace
CONITION POSSIBLE CAUSE CORRETIONS
Trouble in Intake or Exhaust System Air Cleaner Fuel clogged
Air duct kinked or flattened
Replace filter element
Correct or replace
Ignition Failure
------------------------------------------------------
Troubleshooting Guide
Heat range of spark plug inadequate
Refer to "Hard Start"
[Page 10}
Engine Overheating
CONTITION POSSIBLE CAUSE CORRECTIONS
Engine Overheating Level of Engine Coolant too low
Fan clutch defective
Incorrect fan installed
Thermostat defective
Engine Coolant pump defective
Radiator clogged
Radiator filter cap defective
Level of oil in engine crankcase too low or wrong engine oil
Resistance in exhaust system increased
Throttle Position Sensor adjustment incorrect
Throttle position Sensor circuit open or shorted
Cylinder Head gasket damaged
Replenish
Replace
Replace
Replace
Correct or replace
Clean or replace
Replace
Change or replenish
Change or replace
Replace with Throttle Valve ASM
Correct or replace
Replace
Engine Over Cooling Thermostat defective Replace (Use a thermostat set to open at 82 C (180 F)
Engine lacks compression ------------------------ Refer to "Hard Start"
Other Tire inflation pressure abnormal
Brake drag
Clutch slipping
Level of oil in engine crankcase too high
Exhaust Gas Recirculation Valve defective
Adjust to recommended pressure
Adjust
Adjust or replace
Correct level of engine oil
Replace
Engine Noisy:Abnormal engine noise often consists of various noise originating in rotating parts, sliding parts and other moving parts of the engine.
It is, therefore, advisable to locate the source of noise systematically.
[Page 11]
Noise from Journals
CONDITION POSSIBLE CAUSE CORRECTIONS
Noise from crank journals or from crank bearings.
(Faulty crank journals and crank bearings usually making
dull noise that becomes more evident when accelerating)
Oil clearance increased due to worn crank journals or crank bearings

Crankshaft out or round

Crank bearing seized

Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearings


Replace crank bearing and crankshaft or regrind crankshaft and install the undersize bearings
Crank bearing seized. Replace crank bearings and crankshaft or regrind crankshaft and install the undersizebearing
Troubleshooting Procedure:
Short out each spark plug in sequence using the insulate spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops with spark plug
is shorted out
[Page 12]
]Noise from Journals
SERVICE PROCAUTION CAUTION
WARNING: If so equipped with a supplemental restraint system (SRS), refer tot he SRS component and wiring location view in order to determine whether you are performing
service on or near the SRS components or the SRS wiring. When you are performing service on or near the SRS component or the SRS wiring, refer to the SRS
service information. Failture to follow warnings could result in possible air bag deployment, personal injury, or otherwise unneeded SRS system repairs

Always use the correct fastener in the proper location. When you replace a fastener, use only the exact part number for that application, Isuzu will call out those
fasteners that require a replacement after removal. Isuzu will also call out the fasteners that require thread lockers or thread sealant, Unless otherwise specified,

DO NOT USE supplemental coatings (paints, greases, or other corrosion inhibitors) pm threaded fasteners or fastener joint interfaces. generally, such coatings
adversely affect the fasteners torque and joint clamping force, and may damage the fastener. When you install fasteners , sue the correct tightening sequence and
specifications. Following these instructions can help you avoid damage to parts and systems.
GENERAL DESCRIPTION
ENGINE CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.
1. A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation.
2. Whenever valve train components, pistons,piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order.
3. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.
4. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.
5. The six cylinders of this engine are identified by numbers; Right Side Cylinder 1,3 and 5, Left Side Cylinders 2,4, and 6, as counted from crankshaft pulley side to flywheel side.
GENERAL INFORMATION OF ENGINE SERVICE
The following information on engine service should be noted carefully, as it is important in preventing damage and contributing to reliable engine performance:
1. When raising or supporting the engine for any reason, do not use a jack under the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick-up unit.
2. The 12-volt electrical system is capable of damaging circuits. When performing any work when electrical terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.
3. Any time the intake air duct or air cleaner is removed,the intake opening should be covered. This will protect against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.
CYLINDER BLOCK
The cylinder block is made of aluminum die-cast casting the 75* V-type six cylinders. It has a rear plate integrated structure and employs a deep shirt. The cylinder liner is cast and the liner inner diameter and crankshaft journal diameter are classified into grades. The crankshaft is supported by four bearings of which width of No. 3 bearing on the body side is different in order to support the thrust bearing. The bearing cap is made of nodular cast iron on and each bearing cap uses four bolts and two sided bolts.
ENGINE DIAGNOSIS
[Page 13]
HEADLIGHTS GO OUT OR DIM
CONDITION POSSIBLE CAUSE CORRECTIONS
Headlights go out or dim considerably Battery run down or under charged
Terminals poorly connected
Starting motor coil circuit shorted
Starting motor defective
Recharge or replace battery
Clean battery posts and terminal and connect properly
Overhaul or replace
Overhaul or replace
2. Ignition Trouble--starting Motor Turns Over But Engine Not Start
SPARK TEST
Disconnect an ignition coil from any spark plug. Connect the spark plug tester, start engine, and check if a spark is generated in the spark plug tester. before starting the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the part where insulation of the ignition coil is broken while the engine is running.
CONDITION POSSIBLE CAUSE CORRECTIONS
Spark jumps across gap Spark plug defective
Ignition timing incorrect
Fuel not reaching fuel injector(s) or engine
Valve timing incorrect
Engine lacks compression
Clean, adjust spark gap or replace
refer to Ignition System
Refer to item #3 (Trouble in fuel system)
Adjust
Refer to item #4 (Engine lacks compression)
No sparking takes place Ignition coil disconnected or broken
Electronic Ignition system with module
Poor connections in engine harness
Power-Train Control Module cable disconnect or defective
Connect properly or replace
Replace
Correct