Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Service manual — part 575
6A – 138 ENGINE MECHANICAL
1. Timing
Gear
Case
1) Tighten the timing gear case with timing gear case
gasket to the specified torque.
Timing Gear Case Bolt Torque
kg·m (lb.ft/N·m)
1.9
± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
2. Camshaft
Thrust
Plate
Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.
Thrust Plate Bolt Torque
kg·m (lb.ft/N·m)
1.8
± 0.5 (13.0 ± 3.6/17.6 ± 4.9)
3. Camshaft Timing Gear
1) Install the camshaft timing gear to the camshaft.
The timing gear mark (“Y – Y” or “:”) must be facing
outward.
2) Tighten the timing gear to the specified torque.
Timing Gear Bolt Torque
kg·m (lb.ft/N·m)
11.0
± 1 (79.6 ± 7.2/107.8 ± 9.8)
4. Crankshaft Timing Gear
Use the crankshaft timing gear installer
to install the
crankshaft timing gear
.
The crankshaft timing gear setting mark (“X – X” or “・”)
must be facing outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0
5. Idler Gear Shaft
6. Idler Gear “A”
1) Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole
A
must be facing up.
2) Position the idler gear setting marks “X” or “・”, “Y” or
“:” and “Z” or “∴” so that they are facing the front of
the engine.
ENGINE MECHANICAL 6A – 139
3) Align the idler gear “X” or “:” setting mark with the
crankshaft timing gear
“X – X” or “:” setting mark.
4) Align the idler gear “Y” or “・” setting mark with the
camshaft timing gear
“Y – Y” or “・” setting mark.
5) Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
6) Tighten the idler gear bolt to the specified torque.
Idler Gear “A” Bolt Torque
kg·m (lb.ft/N·m)
3.0
± 0.5 (21.7 ± 3.6/30 ± 5.0)
7. 7a. Idler Gear “B” and Shaft
1) Apply engine oil to the idler gear and the idler gear
shaft.
2) Align the idler gear “B”
“Z” or “∴” setting mark with
the idler gear “A”
“Z – Z” or “∴” setting mark.
3) Tighten the idler gear bolt to the specified torque.
Idler Gear “B” Bolt Torque
kg·m (lb.ft/N·m)
7.7
± 1.0 (55.7 ± 7.2/74 ± 9.8)
7a. If the idle gear “B” is disassemble, reassemble in the
following procedure.
Idle Gear B (scissor gear) Reassembly Steps (4JA1TC,
4JH1TC only)
1) Drive pins into the main gear, the front gear, and the
rear gear.
2) Apply pressure to the main gear bearing from the front
side of the main gear (the side with the groove).
020L200019
020L200007
6A – 140 ENGINE MECHANICAL
3) Place the special tool in a vise so that the main gear is
pushed up toward the rear side.
Scissor gear setting tool
Base 5-8673-9149-0
4) Set the spring as shown in the illumination.
5) Position the rear gear so that it pin is aligned with the
receiving end of the spring.
6) Install the snap ring to the main gear groove.
7) Set the rear gear setting hole to the pin of the special
tool.
8) Place the special tool in a vise so that the main gear is
pushed up toward the front side.
9) Repeat Steps 3, 4, and 5.
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ENGINE MECHANICAL 6A – 141
10) Use the special tool to mesh the teeth of the front
gear, the main gear, and the rear gear.
Scissor gear setting tool
Lever 5-8673-9150-0
11) Insert a lock bolt (M6×1 L=30) into the scissor gear
fixing hole to prevent the scissor gear from turning.
8. Timing Gear Oil Pipe (Except 4JA1TC, 4JH1TC)
1) Install the oil pipe to the timing gear case and idler
gear “A”.
2) Tighten the oil pipe eye bolt
and bolt
to the
specified torque.
Eye Joint and Bolt Torque
kg·m (lb.ft/N·m)
1.25
± 0.25 (9.0 ± 1.8/12.3 ± 2.5)
9. Injection
Pump
1) Install
the
O-ring
to the injection pump flange
.
2) Install the injection pump to the timing gear case.
Align the idler gear “B”
“V – V” or “‥” mark with the
injection pump timing gear
“V” or “‥” mark.
020L200014
020L200012
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