Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 705
6A–1
ENGINE MECHANICAL
TROOPER
ENGINE
CONTENTS
Engine Mechanical
6A
. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling
6B
. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel
6C
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Engine Electrical
6D1
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Ignition System
6D2
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Starting and Charging System
6D3
. . . . . . . . . . . .
Driveability and Emissions
6E
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Engine Exhaust
6F
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Engine Lubrication
6G
. . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System
6H
. . . . . . . . . . . .
Inducton
6J
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL
CONTENTS
Service Precaution
6A–2
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General Description
6A–3
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Engine Diagnosis
6A–4
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Cylinder Head Cover LH
6A–19
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Removal
6A–19
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Installation
6A–20
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Cylinder Head Cover RH
6A–21
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Removal
6A–21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
6A–21
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Common Chamber
6A–22
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Removal
6A–22
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Installation
6A–22
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH
6A–24
. . . . . . . . . . . . . . . . . . . . .
Removal
6A–24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
6A–24
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH
6A–25
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Removal
6A–25
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Installation
6A–25
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Crankshaft Pulley
6A–26
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Removal
6A–26
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Installation
6A–26
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Timing Belt
6A–27
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Removal
6A–27
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Installation
6A–28
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Camshaft
6A–32
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Removal
6A–32
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Installation
6A–32
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Cylinder Head
6A–35
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Removal
6A–35
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Installation
6A–35
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Valve Stem Oil Controller , Valve Spring and
Valve Guide
6A–37
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
6A–37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
6A–37
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Piston, Piston Ring and Connecting Rod
6A–38
. . .
Removal
6A–38
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Installation
6A–39
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Crankshaft and Main Bearings
6A–40
. . . . . . . . . . . .
Removal
6A–40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
6A–41
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Rear Oil Seal
6A–45
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Removal
6A–45
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Installation
6A–45
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Engine Assembly
6A–46
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Removal
6A–46
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Installation
6A–47
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Cylinder Head
6A–49
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Cylinder Head and Associated Parts
6A–49
. . . . .
Disassembly
6A–50
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Clean
6A–50
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Inspection and Repair
6A–50
. . . . . . . . . . . . . . . . . .
Reassembly
6A–51
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Valve Spring, Oil Controller, Valve, Valve
Guide
6A–53
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Valve Spring, Oil Controller, Valve, Valve
Guide and Associated Parts
6A–53
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Disassembly
6A–53
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Inspection and Repair
6A–54
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Reassembly
6A–57
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Valve Clearance Adjustments
6A–58
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Camshaft
6A–60
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Camshaft and Associated Parts
6A–60
. . . . . . . . .
Disassembly
6A–60
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
6A–61
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Reassembly
6A–63
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Crankshaft
6A–66
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Crankshaft and Associated Parts
6A–66
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Disassembly
6A–67
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Inspection and Repair
6A–67
. . . . . . . . . . . . . . . . . .
Inspection and Repair
6A–68
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Reassembly
6A–70
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6A–2
ENGINE MECHANICAL
Piston and Connecting Rod
6A–74
. . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts
6A–74
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
6A–74
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
6A–75
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Reassembly
6A–79
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Cylinder Block
6A–81
. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block and Associated Parts
6A–81
. . . . .
Disassembly
6A–81
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
6A–82
. . . . . . . . . . . . . . . . . .
Reassembly
6A–83
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Main Data and Specification
6A–86
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Special Tool
6A–92
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Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE 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
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: 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) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6A–3
ENGINE MECHANICAL
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.
D
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
D
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.
D
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
D
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.
D
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on 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:
D
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
D
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
D
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
for 75
°
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. 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 and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.
6A–4
ENGINE MECHANICAL
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Possible cause
Correction
Headlights go out or dim
Battery run down or under charged
Recharge or replace battery
considerably
Terminals poorly connected
Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted
Overhaul or replace
Starting motor defective
Overhaul or replace
Headlights stay bright
Starting motor circuit open
Refer to Starting and Charging
System
Starting motor coil open
Replace
2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an igniton coil from any spark plug. Connect
the spark plug tester J–26792 (ST–125), 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 igniton coil is
broken while the engine is running.
Condition
Possible cause
Correction
Spark jumps across gap
Spark plug defective
Clean or replace
Ignition timing incorrect
Refer to Ignition System
Fuel not reaching fuel injector(s) or
engine
Refer to item 3 (Trouble in fuel
system)
Valve timing incorrect
Adjust
Engine lacks compression
Refer to item 4 (Engine lacks
compression)
No sparking takes place
Ignition coil disconnected or broken
Connect properly or replace
Ion sensing module defective
Replace
Ion sensing module cable broken or
poor connections
Correct or replace
Poor connections in engine harness
Correct
Powertrain Control Module cable
disconnected or defective
Correct or replace
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