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)


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.

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 Auto Tech Internship/Apprenticeship website click below: Auto Tech Internship/Apprenticeship

Note: After engine has been removed from vehicle and engine has been disassembled

  • Cylinder head screws
  • Flex plate torque converter screws/bolts
  • Old piston pins
  • O-Rings

Fly wheel screws, known by most inexperienced as bolts which are actually called screws, add a nut then it a bolt

The Vehicle discussed in this project is a 2002 Isuzu Trooper LS 3.5L V6 DOHC 5 Door-4 Wheel Drive

    NOTE: Replace
  • "All" O-Rings
  • Air cleaner filters
  • Timing belt
  • "All" Questionable parts, NOTE: Any necessary repairs
  • Spark plugs
  • Coolant
  • Power steering fluids
  • Engine oil
  • Oil filter
  • Hoses
  • Drive belts
  • Transmission fluids
  • Fasteners, use only exact part numbers
  • Control lever assembly
  • Air Conditioning refrigerant
  • Compressor oil
  • Tires

Step 1:After relieving the fuel system pressure. Disconnect the negative battery cable. Drain the engine coolant. Drain the engine oil. The engine will have
an additional ground cable connected from the engine to the frame; this can be disconnected later after components have been removed to give easier access to
the ground cable to be disconnected from the engine. (Drain the radiator coolant into a container to be environmentally legal and dispose in a safe manner, if a
backyard mechanic, keep coolant out of reach of animals.)

(The fuel pressure control valve mounted on the fuel rail maintains a pressure differential across the injectors under all operation conditions. It is accomplished by controlling the amount of fuel that is recirculated back to the fuel tank based on engine demand. Relieve the fuel pressure by connecting a fuel pressure gauge to the fuel pressure connection on the fuel rail.) Fuel pressure is (41-46 psi engine running. In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge; dispose the shop towel in approved container when the task is finished. Disconnect the fuel pump relay and crank the engine to relieve the fuel pressure.

Step 2: Make alignment marks on engine hood and hinges before removal in order to return the hood to original position exactly, remove engine hood, replace the hood screws back in their original location on the hood hinge, (place fender cover on roof of vehicle, place hood on the top fender cover).

Step 3:
  • Remove the air cleaner assembly
  • Remove the intake air cleaner housing
  • Remove the drive belt

Step 4: Remove the intake manifold cover, power brake booster hose and the quick-connect fitting cover, and then disconnect the fuel feed hose. always plug any fuel line, thread a screw into all disconnected fuel line and/or hoses and plug them so dirt will not enter the lines.

Step 5: Disconnect the evaporative emission canister hose. Remove the intake manifold bracket.

Step 6: Remove the engine wire harness connectors and the wire harness clamps from the cylinder head and intake manifold. Remove the four fuel injector

Step 7: Disconnect the engine coolant temperature sensor connector, throttle body connector, and the Air/Fuel (A/F) sensor connector. These connectors
are connected to the wire harness

Step 8: Disconnect the manifold absolute pressure connector, rocker arm oil control solenoid connector, rocker arm oil pressure switch connector, and the
Crankshaft Position (CKP) sensor connector.

As each step is explained there will photo's included to help you understand each step, the photos will be include to help you follow along better.

This Trooper 3.5L blew a #2 rod bearing, the bearing just, causing the crankshaft to push the rod up the cylinder wall farther than designed for, this caused the
piston to band into the head, but did not damage the head. The engine had small metal particles throughout the entire engine system.

The engine had to be pulled and cleaned. there was damage to the crankshaft which had to be taken to a machine shop to be repaired, the cylinder wall were
measured and were anywhere from 0.003 to 0.005 so the block had to be bored, honed, and cleaned.

There are three different criteria's that must be met before deciding purchase a vehicle and/or pull an engine and do the rebuild. The vehicle must met two requirements.
  • 1. Good body
  • 2. Good interior
  • 3. Good engine
  • The Isuzu Trooper met two of the criteria's requirements

  • 1. Excellent body
  • 2. Excellent interior

So it was worth doing the rebuild.

Follow these steps to remove engine from vehicle:

REMOVAL: Preparation

  • Space stands and remove front tires.
  • Remove battery
  • Drain coolant
  • Disconnect window washer hose and remove engine hood
  • 1. Radiator hose

  • Disconnect upper and lower hoses from engine side
  • 2. Fan Shroud

  • Disengage clips and remove upper and lower fan shrouds
  • 3. Cooling Fan Assembly

  • Remove cooling fan ASM fixing nuts, cooling fan ASM, fan pulley and center
  • 4. Radiator Assembly

  • Remove bracket and radiator ASM.
  • 5. Air Cleaner Cover & Air Duct 6. Intercooler Assembly (4JG2-T only)

    7. P/S Pump Drive Belts

  • Loosen P/S pump fixing bolts and adjusting bolt and remove two drive belts
  • 8. P/S Pump Assembly

  • Remove 2 fixing bolts (front side), a fining nut (rear side) and support P/S pump ASM with oil hoses by tying to body side.
  • 9. Engine Ground Cable

  • Disconnect ground cable from A/C compressor bracket
  • 10. A/C Generator Harness

  • Disconnect B terminal and harness connector from A/C generator.
  • 11. A/C Compressor Assembly

  • Remove A/C compressor fixing bolt (rear under side of compressor) by using a long extension bar under side of wheel arch.
  • Disconnect magnetic clutch harness connector.
  • Remove fixing bolts (upper and front lower side of compressor) and set A/C compressor ASM with pipe lines on battery carrier.
  • 12. Vacuum Hose: Vacuum Pump

  • Disconnect vacuum hose from vacuum pump.
  • 13. Starter Harness

  • Disconnect B terminal and put cable harness close to chassis side.
  • Disconnect S terminal connector.
  • 14. Engine Harness.

  • Disconnect engine harness close to engine side.
  • 15. Accelerator Cable

  • Loosen locking nut at bracket and disconnect Accelerator cable from injection pump control lever.
  • 16. Fuel Hose

  • Disconnect fuel hoses from injection pump side and take care not to spill fuel and enter dust.
  • 17. Engine Ground Cable

  • Disconnect ground cable from left rear side of timing gear case.
  • 18. Vacuum Hose: Vacuum Tank

  • Disconnect vacuum hose from vacuum pump side.
  • 19. Remove glow plug harness

    20. Transmission Assembly

  • Install special tools (engine hangers) in front right and left rear sides of cylinder head.
  • Front right side; use the ground cable fixing bolt on A/C compressor bracket.
  • Left rear side; fix hanger together with oil cooler hose clip.
  • Engine hanger: 5-8/840-2032-0
  • Left engine carefully by using hoist.
  • 21. Engine Mounting

  • Remove fixing bolts (both left and right side) using extension bar and box wrench at under side of wheel arches
  • 22. Engine Assembly

  • Install special tools (engine hangers) in left rear and front right sides of cylinder head.
  • Lift engine carefully by using hoist.
  • Lift front part of engine higher than rear part of it.
  • Take out engine ASM taking care not to damage full pipes, brake pipes and etc.