Isuzu Trooper (1998-2002 year). Service manual — part 559
6A – 44 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove air cleaner and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Remove PCV hose.
7. Remove EGR vacuum hose.
8. Disconnect harness connector around the cylinder
head.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out fan belt.
12. Remove heat protector and remove valve
assembly.
13. Remove water hose and oil pipe from turbocharger.
14. Remove turbocharger assembly.
15. Remove water hose between thermostat and
radiator.
16. Remove cylinder head noise insulator cover.
NOTE: Do not make damage to the harness.
17. Remove high pressure pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner and remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove water pipe between cylinder head and
water pump.
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe.
26. Remove intake manifold assembly.
27. Disconnect glow plug wiring and remove glow plug.
28. Remove cylinder head cover.
29. Drain oil from oil rail.
30. Disconnect injector harness connector.
31. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
32. Disconnect injector harness assembly.
33. Remove injector clamp.
34. Remove injector spacer (If equipped.).
35. Remove injector assembly.
36. Remove oil rail assembly.
37. Remove camshaft carrier.
38. Remove cylinder head assembly.
39. Remove cylinder gasket.
INSTALLATION
1. Install cylinder head gasket with top mark up.
NOTE: Determine cylinder head gasket grade by
measuring projection of piston head.
2. Selection cylinder head gasket.
1) Measure the piston head projection by dial
gauge.
2) Measure the projection of piston head at the
nearest possible point to the cylinder bore.
3) Obtain the largest measurement from among all
cylinders.
4) Determine cylinder head gasket grade by
maximum value of measuring projection of
piston head.
Legend
(1) Top Mark
(2) Grade Mark
012RW073
2
1
011RW043
ENGINE MECHANICAL 6A – 45
Cylinder head gasket and piston projection
mm
CAUTION:
•
The projection of each piston should be 0.333
mm or more and less than 0.483 mm.
•
Maximum difference in projection between
pistons should be less than 0.1 mm.
•
If the piston projection is without standard,
reassemble the engine all over again.
3. Install cylinder head assembly, tighten bolts by
angular tightening method.
Torque:
1st step;
49 N·m (5.0 kg·m/36 lb ft)
2nd step; 60°
3rd step; 60°
CAUTION: The cylinder head bolts cannot be
reused.
4. Install camshaft carrier assembly.
Refer to “Camshaft” in this manual.
5. Install oil rail and injector assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector harness to connect harness
connector.
Note: Apply liquid gasket (TB 1207B or equivalent) to
the rubber seal of the camshaft end, injector harness
gasket area and No. 1 camshaft bracket. Refer to the
Cylinder head cover.
7. Install cylinder head cover.
Torque: 9 N·m (0.9 kg·m/78 lb in)
8. Install glow plug to tighten specified torque.
Torque: 15 N·m (1.5 kg·m/11 lb ft) and connect
glow plug harness.
9. Install intake manifold.
Torque: 20 N·m (2.0 kg·m/14 lb ft)
10. Install fuel return pipe.
11. Install fuel pipe in between fuel pump and intake
manifold.
12. Install water pipe in between cylinder head and
water pump.
Tighten flange bolt to the specified torque.
Torque: 20 N·m (2.0 kg·m/14 lb ft)
13. Install front plate.
Torque: 20 N·m (2.0 kg·m/14 lb ft)
14. Install camshaft pulley, tighten with angular
tightening method.
1st step 40 N·m (4.1 kg·m/30 lb ft)
2nd step 60°
NOTE: Apply engine oil to camshaft pulley bolt.
15. Align timing mark oil pump pulley and camshaft
pulley to front plate then put the timing belt and
tighten tensioner bolt.
Torque: 20 N·m (2.0 kg·m/14 lb ft) for M8
50 N·m (5.1 kg·m/37 lb ft)
16. Install CMP sensor bracket.
17. Install timing belt cover.
Torque: 9 N·m (0.9 kg·m/78 lb in)
18. Fill with about 300 cc of engine oil from the high
pressure oil pipe installing port of oil rail using an oil
filler.
If assembled without filling the oil rail with oil, the
time for engine start will be longer.
19. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 78 N·m (8.0 kg·m/58 lb ft)
20. Install cylinder head noise insulator cover.
Torque: 9 N·m (0.9 kg·m/78 lb in)
Grade A
Grade B
Grade C
011RW042
Grade
Piston projection
Gasket
thickness
A
more 0.333 to less 0.383
1.35
B
more 0.383 to less 0.433
1.40
C
more 0.433 to less 0.483
1.45
6A – 46 ENGINE MECHANICAL
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt, Stud and Rubber Mounting
21. Install water hose between thermostat and radiator.
22. Install turbocharger assembly to exhaust manifold.
Torque: 27 N·m (2.8 kg·m/20 lb ft)
23. Install water hose and oil pipe for turbocharger.
24. Install exhaust valve assembly and heat protector.
Torque: 57 N·m (5.8 kg·m/42 lb ft) for valve
Torque: 9 N·m (0.9 kg·m/78 lb in) for heat protector
25. Install generator assembly.
Torque: 40 N·m (4.1 kg·m/30 lb ft) for ACG bracket
Torque: 40 N·m (4.1 kg·m/30 lb ft) between ACG and
bracket
Torque: 20 N·m (2.0 kg·m/14 lb ft) between ACG
and adjuster plate
26. Fix the A/C compressor bracket and install A/C
compressor.
Torque: 46 N·m (4.7 kg·m/34 lb ft) for A/C bracket
Torque: 20 N·m (2.0 kg·m/14 lb ft) for belt tensioner
27. Reconnect harness connector around cylinder
head.
28. Connect EGR vacuum hose.
29. Install oil level gauge guide assembly.
Tighten nuts lower portion and tighten bolt.
Torque: 20 N·m (2.0 kg·m/14 lb ft)
30. Install intercooler assembly.
Refer to “Intercooler” in this manual.
31. Install air duct between air cleaner and
turbocharger.
32. Fill engine coolant.
33. Reconnect battery.
For Europe
025R200007
For Europe
025R200006
1
7
2
3
4
5
6
010R200006
ENGINE MECHANICAL 6A – 47
CAMSHAFT
2
1
6
With
spacer type
Without
spacer type
13
14
8
12
11
10
9
3
4
7
5
012R200004
Legend
(1)
Nut and Washer
(2)
Injector Clamp
(3)
Nut
(4)
Bolt
(5)
Oil Rail Assembly
(6)
Spacer (If equipped) and Bolt
(7)
Injector Assembly
(8)
Camshaft
(9)
Camshaft Carrier
(10)
Plug
(11)
Oil Seal
(12)
Camshaft Bracket
(13)
Gasket
(14)
Gasket
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