Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 569
6A – 114 ENGINE MECHANICAL
Important Operations
3. Valve Stem Oil Seal
1) Apply a coat of engine oil to the oil seal inner face.
2) Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
1) Apply a coat of engine oil to each valve stem before
installation.
2) Install the intake and exhaust valves.
3) Turn the cylinder head up to install the valve springs.
Take care not to allow the installed valves to fall free.
5. Valve
Spring
Install the valve spring with their fine pitched end (painted)
facing down.
7. Split
Collar
1) Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0 (J-29760)
2) Install the split collars to the valve stem.
3) Set the split collars by tapping around the head of the
collar with a rubber hammer.
8. Intake Manifold Gasket
9. Intake
Manifold
1) Install the manifold gasket with the end having the
sharp corners facing the front of the engine.
2) Install the intake manifold to the cylinder head.
3) Tighten the manifold bolts to the specified torque.
Manifold Bolt Torque
kg·m (lb.ft/N·m)
1.9
±
0.5 (13.7
±
3.6/18.6
±
4.9)
ENGINE MECHANICAL 6A – 115
PISTON AND CONNECTING ROD
Reassembly Steps
t
1.
Piston
t
5.
Piston pin snap ring
t
2.
Piston pin snap ring
t
6.
Piston ring
t
3.
Connecting rod
t
7.
Connecting rod bearing
t
4.
Piston pin
015L200003
For 4JA1/4JA1T/4JA1TC
/4JH1TC only
6A – 116 ENGINE MECHANICAL
Important Operations
1. Piston
2. Piston Pin Snap Ring
3. Connecting Rod
1) Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2) Use a pair of pliers to install the piston pin snap ring to
the piston.
Install the piston to the connecting rod so that the piston
head front mark
c
and the connecting rod “ISUZU”
casting mark
d
are facing in the same direction.
4. Piston
Pin
1) Apply a coat of engine oil to the piston pin and the
piston pin hole.
2) Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
5. Piston Pin Snap Ring
3) Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
4) Check that the connecting rod moves smoothly on the
piston pin.
015R100022
015R100018
ENGINE MECHANICAL 6A – 117
6. Piston
Ring
1) Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
c
Oil ring
d
2nd compression ring
e
1st compression ring
Note:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
2) Apply engine oil to the piston ring surfaces.
3) Check that the piston rings rotate smoothly in the
piston ring grooves.
7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.
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