Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 554

6A – 54 ENGINE MECHANICAL

ENGINE REPAIR KIT

All of the numbered parts listed below are included in the Engine Repair Kit.
The gaskets marked with an asterisk (*) are also included in the Top Overhaul Kit.

* 1.

Cylinder head gasket

12.

Water pump O-ring

* 2.

Head cover gasket

*

13.

Water outlet pipe gasket

* 3.

Head cover cap nut gasket

*

14.

Intake pipe gasket

4.

Drain cock gasket

15.

Thermostat housing gasket

5.

Crankshaft rear oil seal

*

16.

Intake manifold gasket

6.

Gear case gasket

*

17.

Exhaust manifold gasket

7.

Oil pan drain plug gasket

*

18.

Nozzle holder O-ring

8.

Oil pan gasket

*

19.

Nozzle holder gasket

9.

Oil filter gasket

20.

Crankshaft front oil seal

10.

Joint bolt gasket

21.

EGR Cooler gasket (4JA1TC
only)

11.

Vacuum pump gasket

22.

Inter cooler outlet pipe gasket
(4JA1TC, 4JH1TC only)

ENGINE MECHANICAL 6A – 55

ENGINE OVERHAUL

REMOVAL

EXTERNAL PARTS

These removal steps are based on the 4JB1T engine.
The triangle (

J

) mark indicates the important operations.

Removal Steps

1.

Cooling fan drive belt

16.

Turbocharger heat protector

2.

Cooling fan pulley

17.

Exhaust adaptor

3.

Heater pipe (rear side)

18.

Turbocharger oil return pipe

4.

Oil level gauge and guide tube

19.

Turbocharger oil feed pipe

5.

Starter motor

J

20. Turbocharger

6.

Water drain cock

21.

Exhaust manifold heat protector

7.

Oil pressure warning switch and

22.

Oil cooler with Oil filter

nipple

23.

Exhaust

manifold

8.

Engine mounting bracket

24.

Compressor bracket

J

9.

Intake manifold

25.

Generator bracket

J

10.

Fuel injection pipe with clip

26.

Power steering oil pump

11.

Fuel leak off pipe

27.

Vacuum pipe

12.

Injection pump

13.

Compressor

14.

Generator and adjusting plate

15.

Water inlet pipe

6A – 56 ENGINE MECHANICAL

Important Operations

9. Intake

Manifold

1) Disconnect the PCV hose from the cylinder head

cover.

2) Disconnect the intake duct and intake rubber hose

from the turbocharger.

3) Remove the upper intake manifold the lower intake

manifold with intake duct, and the PCV hose.

10. Fuel Injection Pipe with Clip

1) Loosen the injection pipe sleeve nuts at the delivery

valve side

Q

and injection nozzle side.

Do not apply excessive force to the injection pipes.

2) Loosen the injection pipe clips

R

.

3) Remove the injection pipes

S

.

Note:
Plug the delivery holder ports with the shipping caps
to prevent the entry of foreign material.

20. Turbocharger

Plug the turbocharger body oil ports after removing the
turbocharger assembly to prevent the entry of foreign
material.

ENGINE MECHANICAL 6A – 57

INTERNAL PARTS

MAJOR COMPONENTS

Disassembly Steps-1

1.

Water bypass pipe

5.

Glow plug and glow plug

2.

Thermostat housing with thermo

connector

switch

J

6.

Rocker arm shaft and rocker

3.

Cylinder head cover

arm

J

4.

Injection nozzle and Injection

7.

Push rod

nozzle

holder

J

8.

Cylinder head

4a. Injection nozzle (4JG2T)

9.

Cylinder head gasket

4b. Injection nozzle and Injection

Nozzle holder (4JA1TC, 4JH1TC)

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