Isuzu Trooper (1998-2002 year). Manual — part 566
6A – 72 ENGINE MECHANICAL
CRANK CASE
REMOVAL
1. Drain engine oil.
2. Remove transmission assembly.
3. Remove crankshaft damper pulley.
4. Remove timing belt cover, timing belt, pulley and
front plate.
5. Remove timing gear case cover.
6. Remove timing gears.
NOTE: Do not forget to set lock bolt for idle gear A and
lock pin for idle gear C.
7. Remove timing gear case.
8. Remove oil level gauge guide assembly.
9. Remove flywheel assembly.
CAUTION:
1) The flywheel heavy; be careful not to drop it.
2) Be careful no to let it slip because the hexagon
of the bolt is thin.
10. Remove rear plate (for A/T) or flywheel housing (for
MT).
11. Remove retainer.
NOTE:
1) Be careful not to damage the oil seal; it can be
reused.
2) Inspect installation portion for distortion and flow on
the slinger; also inspect for flow on the oil seal lip.
3) If there is some flow oil seal/slinger, replace a set.
12. Remove bolts from thrust plate of balance shaft LH
then remove balance shaft.
13. Loosen crank case fixing bolts.
14. Use seal cutter to take off the liquid gasket.
Seal cutter: 5-8840-2153-0
15. Remove crank case assembly.
CAUTION:
Do not give shock to crank case for prevention take
off applied vibration insulation material on the
crank case.
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2
3
012RW029
Legend
(1)
Crank Case
(2)
Oil Pan
(3)
Drain Plug
ENGINE MECHANICAL 6A – 73
INSTALLATION
1. Install relief valve (if it was removed).
Torque: 30 N·m (3.1 kg·m / 22 lb ft)
2. Apply oil and insert O-ring to strainer, install strainer
and tighten to specified torque.
Torque: 20 N·m (2.0 kg·m / 14 lb ft)
3. Apply liquid gasket (TB1207B or equivalent) to
surface of oil pan and tighten bolt to the specified
torque.
Torque: 22 N·m (2.2 kg·m / 16 lb ft)
4. Apply engine oil to the balance shaft (left) and insert
it into crank case.
NOTE:
•
Do not damage bearing when inserting the balance
shaft.
•
Make sure it rotates smoothly.
5. Tighten thrust plate of balance shaft LH.
Torque: 25 N·m (2.5 kg·m / 18 lb ft)
6. Set O-ring port of oil gallery on the cylinder block.
7. Apply liquid gasket (TB1207C or equivalent) to
crankcase fixing surface then tighten bolts to the
specified torque.
Torque: 24 N·m (2.4 kg·m / 17 lb ft)
NOTE: Make sure there is no oil, dust or scratches on
the surface coated with liquid gasket and mount within
five minutes of gasket application.
8. Install retainer with oil seal.
9. Install rear plate (A/T) or flywheel housing (MT),
tighten bolt to the specified torque.
Torque: 97 N·m 9.9 kg·m / 72 lb ft)
10. Install flywheel assembly with applied engine oil to
the bolt, tighten the bolt using angular tightening
method.
1st step: 59 N·m (6.0 kg·m / 43 lb ft)
2nd step: 60° to 90°
3rd step: 60° to 90°
11. Install oil level gauge guide assembly.
12. Install timing gear case.
Torque: 20 N·m (2.0 kg·m / 14 lb ft)
13. Install timing gears
Refer to “Timing Gear” in this manual.
14. Remove lock bolt from idle gear A and remove lock
pin from idle gear C.
15. Install timing gear case cover.
Torque: 20 N·m (2.0 kg·m / 14 lb ft)
16. Install oil pump pulley.
Torque: 10 N·m (1.0 kg·m / 87 lb in)
17. Install camshaft pulley tighten bolt with angular
tightening method.
Torque:
1st step: 40 N·m (4.1 kg·m / 30 lb ft)
2nd step: 60° to 90°
18. Install timing belt and belt tensioner.
Refer to “Timing Gear” in this manual.
19. Install crankshaft damper pulley.
Torque: 216 N·m (22 kg·m / 159 lb ft)
20. Fill engine oil.
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001
6A – 74 ENGINE MECHANICAL
CRANKSHAFT
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15
14
13
8
11
16
17
10
9
7
2
12
3
4
6
5
18
012RW023
Legend
(1)
Cylinder Head
(2)
Cylinder Head Gasket
(3)
Flywheel
(4)
Cylinder Block Rear Plate (for A/T) or Flywheel
Housing (for M/T)
(5)
Crankshaft Rear Oil Seal
(6)
Retainer
(7)
Timing Gear Case
(8)
Crankshaft Front Oil Seal
(9)
Timing Gear Case
(10)
Gasket
(11)
Balance Shaft
(12)
Crank Case
(13)
Piston Cooling Oil Pipe
(14)
Main Bearing Cap
(15)
Crankshaft
(16)
Crankshaft Timing Gear
(17)
Piston and Connecting Rod Assembly
(18)
Cylinder Block
ENGINE MECHANICAL 6A – 75
DISASSEMBLY
1. Cylinder Head
1) Refer to “Cylinder head” in this manual.
2. Crankshaft Front Oil Seal
1) Use a plastic hammer and a screwdriver to tap
around the oil seal to free it from the gear case
cover.
Take care not to damage the oil seal fitting
surfaces.
3. Crankshaft Timing Gear
4. Timing Gear Case
5. Flywheel
6. Cylinder Block Rear Plate
7. Crankshaft Rear Oil Seal
1) Use special tool to remove the crankshaft rear
oil seal.
Oil Seal Remover: 5-8840-2360-0
8. Crank Case
9. Piston Cooling Oil Pipe
10. Piston and Connecting Rod Assembly
11. Main Bearing Cap Assembly
12. Crankshaft
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
1. Crankshaft Thrust clearance
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified limit,
replace the thrust bearing as a set.
Standard : 0.04 – 0.20 mm (0.0016 – 0.0079 in)
Limit: 0.30 mm (0.0118 in)
2. Main bearing clearance
1) Remove the main bearing caps in the sequence
shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
2) Remove the crankshaft. Remove the main
bearings.
3) Clean the upper and lower bearings as well as
the crankshaft main journal.
4) Check the bearings for damage or excessive
wear.
The bearings must be replaced as a set if
damage or excessive wear is discovered during
inspection.
5) Set the upper bearings and the thrust washers
to their original positions. Carefully install the
crankshaft.
6) Set the lower bearings to the bearing cap
original position.
015LV002
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