Cylinder head torque sequence ISUZU TROOPER 1998 Service Repair Manual

COMPRESSOR OVERHAUL 1D Ð 15
8. Install front valve plate.
·Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin.
NOTE
Do not mix up the front and rear valve plates.
9. Install gasket
·Apply new compressor oil to the new gasket.
·Install the gasket to the valve plate by a aligning it
with the spring pin.
10. Install o-ring.
11. Install front cylinder head.
·Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the front cylinder head.
Install the front cylinder head.
Tap the front cylinder head into place with a
plastic hammer.
NOTE
When installing the cylinder head, be careful
that the end of the drive shaft does not
damage the shaft seal assembly surface in the
cylinder head.12. Install through bolt.
·Gaskets cannot reused. Always replace new
ones. Tighten the bolts to the specified torque a
little at a time in the sequence shown in the
illustration.
Torque: 22Nám (16 lbáft)
NOTE
Rotate the compressor drive shaft two or three
times to make sure that it moves smoothly.
1
4
5
2
3
6
871RY00016
871RY00023

6A±89
ENGINE MECHANICAL
012RS007
7. Install cylinder block side bolts (1) and tighten
crankcase bolts in sequence shown in the illustration.
Torque : 39 N´m (4.0 Kg´m/29 lb ft)
012RW005
8. Install oil pump assembly. Refer to ªOil Pumpº in this
manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB± 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 N´m (1.0 Kg´m/89 lb in)
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to ªCylinder
Headº in this manual.

ENGINE MECHANICAL 6A Ð 31
·Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.
·Apply engine oil to the crankshaft bearing cap bolts.
·Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.
NOTE:
Check to see that the crankshaft turns smoothly by rotating
it manually.
12. Piston and Connecting Rod Assembly
·Apply engine oil to the cylinder bores, the connect-
ing rod bearings and the crankshaft pins and each
piston ring and piston.
Check to see that the piston ring end gaps are
correctly positioned.
29 (3.0/22)
N·m(kg·m/lb.ft) Oiling Jet Plug
10. Oil Pump Assembly
1) Prepare a solution of 80% engine oil and 20%
molybdenum disulfide.
2) Apply an ample coat of the solution to the teeth of
the oil pump pinion.
3) Install the oil pump and tighten the bolts to the
specified torque.After tightening the cap nuts, check to see that the
crankshaft rotates smoothly.
11. Piston Cooling Oil Pipe
·Tighten the bolt and oiling jet plug to the specified
torque ·Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
Piston ring compressor: 5-8840-9018-0
The front marks must be facing the front of the
engine.
·Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.
·Apply engine oil to the threads and seating faces of
the nuts.
·Tighten the cap nuts in 2 steps, using angular tight-
ening method as shown in the following specifica-
tions.
167 (17.0/123)N·m(kg·m/lb·ft)
N·m (kg·m/lb·ft)
45¡ ~ 60¡ 1st step 2nd step
29 (3.0/22)
N·m (kg·m/lb·ft)
19 (1.9/14) M6 8 (0.8/6)
M8

6A Ð 48 ENGINE MECHANICAL
·Apply engine oil to the thrust washer.
·Assemble the thrust washer to the No. 3 bearing
journal. The oil grooves must face the crankshaft.
15. Main Bearing Cap Assembly
·Apply the recommended liquid gasket or its equiva-
lent to the No. 5 crankshaft bearing cap cylinder
body fiting surfaces at points 1 and 2 shown in the
illustration.
NOTE:
Be sure that the bearing cap fitting surface is completely
free of oil before applying the liquid gasket.
Do not allow the liquid gasket to obstruct the cylinder
thread holes and bearings.
·Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.
·Apply engine oil to the crankshaft bearing cap bolts.
·Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.
NOTE:
Check to see that the crankshaft turns smoothly by rotating
it manually.
·Apply the recommended liquid packing or its equiva-
lent to the No. 5 crankshaft bearing cap 3 as shown
in the illustration.
Install the arch packing 4 to the No. 5 bearing cap.
NOTE:
Take care to install the arch packing in the groove of bearing
cap correctly.
Take care not to scratch the arch packing outer surface.
167 (17.0/123)N·m (kg·m/lb·ft)

ENGINE MECHANICAL 6A– 79
Main Bearing Crankshaft
Bore Diameter mm(in) Main Journal Diameter mm(in)Crankshaft Oil Clearance
Grade Inside Diameter Grade Outside DiameterBearing mm(in)
1 or - 69.927 – 69.932 4 0.045 – 0.061
(2.7530 – 2.7532) (0.0018 – 0.0024)
1 73.992 – 74.000 2 or - - 69.922 – 69.927 4 0.050 – 0.066
(2.9131 – 2.9134) (2.7528 – 2.7530) (0.0020 – 0.0026)
3 or - - - 69.917 – 69.922 5 0.052 – 0.068
(2.7526 – 2.7528) (0.0020 – 0.0027)
1 or - 69.927 – 69.932 2 0.042 – 0.059
(2.7530 – 2.7532) (0.0017 – 0.0023)
2 73.983 – 73.992 2 or - - 69.922 – 69.927 3 0.044 – 0.061
(2.9127 – 2.9131) (2.7528 – 2.7530) (0.0017 – 0.0024)
3 or - - - 69.917 – 69.922 4 0.046 – 0.063
(2.7526 – 2.7528) (0.0018 – 0.0025)
1 or - 69.927 – 69.932 1 0.037 – 0.053
(2.7530 – 2.7532) (0.0015 – 0.0021)
3 73.975 – 73.983 2 or - - 69.922 – 69.927 2 0.039 – 0.055
(2.9124 – 2.9127) (2.7528 – 2.7530) (0.0015 – 0.0022)
3 or - - - 69.917 – 69.922 2 0.044 – 0.060
(2.7526 – 2.7528) (0.0017 – 0.0024)
REASSEMBLY
1. Crankshaft
1) Install the main bearings to the cylinder body
and the main bearing caps.
2) Be sure that they are positioned correctly.
3) Apply new engine oil to the upper and lower
main bearing faces.
4) Carefully mount the crankshaft.
5) Apply engine oil to the thrust washer.
6) Assemble the thrust washer to the No. 3 bearing
journal. The oil grooves must face the
crankshaft.7) Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
8) Apply engine oil to the crankshaft bearing cap
bolts.
9) Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.
Torque: 167 N·m (17.0 kg·m/123 lb ft)
NOTE: Check to see that the crankshaft turns smoothly
by rotating it manually.
012RW047
84159
610
23
7
012RW027

ENGINE MECHANICAL 6A– 95
Oil pipe fixing bolts
M8: 20 N·m (2.0 kg·m/14 lb ft)
M6: 8 N·m (0.8 kg·m/69 lb in)
Relief valve fixing bolts : 30 N·m (3.1 kg·m/22 lb ft)
CAUTION: After installing the piston assembly,
check and see that there is appropriate clearance
between pistons and oil jet pipes by rotating
crankshaft slowly.
3. Crankshaft
1) Install the main bearings to the cylinder body
and the main bearing caps.
2) Be sure that they are positioned correctly.
3) Apply new engine oil to the upper and lower
main bearing faces.
4) Carefully mount the crankshaft.5) Apply engine oil to the thrust washer.
6) Assemble the thrust washer to the No. 3
bearing journal. The oil grooves must face the
crankshaft.
4. Main Bearing Cap Assembly
1) Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
2) Apply engine oil to the crankshaft bearing cap
bolts.
3) Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.
Torque: 167 N·m (17.0 kg·m/123 lb ft)
321
012RW076
012RW038
012RW047
12345
012RW025