Isuzu Trooper (1998-2002 year). Service manual — part 563
6A – 60 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drive
belt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
1
2
3
4
5
6
9
10
7
8
011RW031
Legend
(1)
Adjuster
(2)
Tappet
(3)
Split Collar
(4)
Spring Seat Upper
(5)
Valve Spring
(6)
Spring Seat Lower
(7)
Valve Stem Seal
(8)
Valve Guide
(9)
Valve Seat
(10)
Valve
ENGINE MECHANICAL 6A – 61
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe from rear of cylinder head.
26. Remove intake manifold assembly.
27. Disconnect glow plug harness and remove glow
plug.
28. Remove cylinder head cover.
29. Remove injector harness connector.
30. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
31. Remove injector harness assembly.
32. Remove injector clamp.
33. Remove injector is fixed bolts.
34. Remove injector assembly.
35. Remove oil rail.
36. Remove camshaft carrier assembly with camshaft.
37. Remove cylinder head assembly.
38. Disassemble valve spring according to the following
method.
1) Use valve spring compressor then remove split
collars.
2) Valve spring compressor: 5-8840-2441-0
NOTE: Put removed valve spring in order of cylinder
number.
39. Valve stem seal.
1) Use a screwdriver or pliers to remove valve
stem seal.
NOTE: Do not reuse removed valve stem seal.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Valve spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Free height
1) Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit.
Standard: 45.85 mm (1.8051in)
Limit: 43.9 mm (1.7283 in)
2. Squareness
1) Measure the valve spring squareness with a
steel square.
2) Replace the valve springs if the measured value
exceeds the specified limit.
Limit: 1.6 mm (0.063 in)
014rw042
014rs004
014rs005
6A – 62 ENGINE MECHANICAL
3. Spring tension
1) Use a spring tester to compress the springs to
the installed height. Measure the compressed
spring tension.
2) Replace the springs if the measured tension is
below the specified limit.
Standard: 236.0 N (24 kg/53 lb)
Limit: 205.0 N (21 kg/46 lb)
Valve Guide
CAUTION: Taking care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head.
Carefully inspect the valve stem for scratching or
abnormal wear. If these conditions are present, the
valve and the valve guide must be replaced as a set.
1. Valve Guide Clearance
1) Measure the valve stem diameter with a
micrometer.
If the valve stem diameter is less than the
specified limit, the valve and the valve guide
must be replaced as a set.
Diameter of Valve stem:Inlet
Standard: 6.959 – 6.977 mm (0.2740 – 0.2747 in)
Limit: 6.92 mm (0.2724 in)
Diameter of Valve stem:Exhaust
Standard: 6.952 – 6.97 mm (0.2737 – 0.2744 in)
Limit: 6.90 mm (0.2717 in)
2) Measure the inside diameter of the valve guide
with a micrometer.
3) Subtract the measured outer diameter of the
valve stem from the measured inner diameter of
the valve guide.
If the valve exceeds the specified limit, the valve
and the valve guide must be replaced as a set.
Inlet clearance
Standard: 0.023 – 0.053 mm (0.0009 – 0.0021 in)
Limit: 0.19 mm (0.0075 in)
Exhaust clearance
Standard: 0.03 – 0.063 mm (0.0012 – 0.0025 in)
Limit: 0.20 mm (0.0079 in)
014RS006
014RS007
ENGINE MECHANICAL 6A – 63
Valve Guide Replacement
1. Using the special tool, drive out the valve guide
from the combustion chamber side.
Valve guide replacer: 9-8523-1212-0
2. Apply engine oil to the outside of the valve guide.
Using the special tool, drive in a new valve guide
from cylinder head upper face side, and check the
valve guide height.
Valve guide replacer: 9-8523-1212-0
Height: 8.0 mm (0.315 in)
NOTE: If the valve guide has been removed, both the
valve and the valve guide must be replaced as a set.
Valve Thickness
1. Measure the valve thickness.
2. If the measured value is less than the specified
limit, the valve and the valve guide must be
replaced as a set.
Inlet
Standard: 1.2 mm (0.0472 in)
Limit: 1.1 mm (0.0433 in)
Exhaust
Standard: 1.2 mm (0.0472 in)
Limit: 1.1 mm (0.0433 in)
Contact surface angle on valve seat on
valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Standard: 68°
011RW001
012RW052
012RW060
014RW018
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