engine ISUZU TROOPER 1995 Workshop Manual

1,.!.,1 REASSEMBLY
14. Cylinder block
13. Crankshaft
1•1• Install the main bearings to the cylinder block
and the main bearing caps (Fig. 6A-112).
• Be sure that they are positioned correctly.
•
Apply new engine oil to the upper and lower
main bearing faces.
• Carefully mount the crankshaft.
1~·1 .• Apply engine oil to the thrust washer.
Assemble the thrust washer to the No. 3
bearing
journal. The oil grooves must face the
crankshaft (Fig. 6A-113).
r--!::"
11-1
~
Upper and lower
#1,4
Upper
#2,3
Fig. 6A-112
Fig. 6A-113
12. Crankshaft bearing cap
Lower
#2,3
D • Apply engine oil to the threads and the seating
L:J faces of the bolts.
I• I• Install bearing caps in the order shown with the
No.1 as the front most bearing cap (Fig. 6A-114)
• Semitighten all of bolts. Finally, tighten all the
bolts to specification in the order shown (Fig.
6A-115)
Torque
N·m (lb·ft) 39 (29)
After the final tightening, check to see that the
crankshaft rotates
smoothly.
GENERAL ENGINE MECHANICAL &A-39
Forward
Fig. 6A-114
Fig. 6A-115
11. Rear oil seal assembly
• Tighten all the bolts.
~~~ Torque N·m (lb·ft)
1 0. Flywheel
18 (13)
r:l]1) Thoroughly clean and remove the oil from the
threads
of crankshaft.
2) Remove the oil from the crankshaft and
flywheel mounting faces.
3) Mount the flywheel on the crankshaft and then
install the washer.
4) Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown (Fig. 6A-116).
~~~ Torque N·m (lb·ft) 54 (40)
NOTE:
•
Do not reuse the bolts.
•
Do not apply oil or thread lock to the bolts.

6A-40 GENERAL ENGINE MECHANICAL
Fig. 6A-116
9. Piston and connecting rod assembly.
Cl • Apply engine oil to the cylinder bores, the
L:J connecting rod bearings and the crankshaft
pins.
NOTE:
Do not apply engine oil to the bearing back
faces and the connecting rod bearing fitting
surfaces.
• Check to see that the piston ring end gaps are
correctly positioned (Fig. 6A-117).
Oil ring--~~~=!==:::;:,.::~~--No.1 side rail Compression (Lower) ring
Front mark
No. 2--~~~~i::::::=~~;(.,.--Oil ring Compression side rail ring (Upper)
Fig. 6A-117
• Insert the piston/connecting rod assemblies
into each cylinder with the piston ring com­
pressor.
• The front marks must be facing the front of the
engine (Fig. 6A-118).
8.
Front mark
Front mark
Fig. 6A-118
Oil gallery
• Tighten the bolts in 2 steps in the order shown
(Fig. 6A-119).
1~1 _________ 1s_t,s_te~p ________ +-_2_n_d_S_t_e_p ___
7.
N·m (lb·ftl 29 (22) ss· -ss·
Crankcase side bolts (Fig. &A-119)
• Tighten crankcase bolts in sequence shown in
the
illustration.
I~I __ T_o_r~qu_e __ N_·_m __ (lb_·ft_)~ ______ 3_9_(2_9_l ____ _
Q : Oil gallery fixing bolts 0 : Crankcase bolts
Fig. 6A-119
6. Oil pump assembly
• Refer to Section 6A 1 "Oil pump installation".
5. Oil strainer and rubber ring
4.
Oil pipe and rubber ring
•

3. Oil pan
m 1) Completely remove all residual sealant,
t..al lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.
li5il 2) Apply a correct width bead of sealant (TB­
L::!i!J 1207C or its equivalent) to the contact surfaces
of the oil pan. There must be no gaps in the
bead (Fig. 6A-120).
3) The oil pan must be installed within 5 minutes
after sealant application.
4) Tighten the bolts and nuts to the specified
torque.
1«.1 Torque N·m (lb-in) 10 (87)
4.3mm (0.17in.) width bead of sealant
Fig. 6A-120
2. Cylinder head gasket
1. Cylinder head assembly
• Refer to Section 6A 1 "Cylinder head
installation".
GENERAL ENGINE MECHANICAL 6A-41

ENGINE (V6 3.2L DOHC AND SOHC) 6A 1-1
SECTION 6A1
3.2L V6 ENGINE
CONTENTS
General Description .................. 6A1-2 Crankshaft Pulley ................... 6A1-24
Cylinder Block . . . . . . . . . . . . . . . . . . . . . 6A 1-3 Camshaft/Rocker Arm (SOHC) ........ 6A1-25
Cylinder Head ...................... 6A1-3 Camshaft/Swing Arm/Hydraulic Lash
Valve Train ........................ 6A1-3 Adjusters (DOHC) ................. 6A1-29
Intake Manifold .................... 6A1-3 Timing Chain (DOHC) ................ 6A1-33
Exhaust Manifold ................... 6A1-3 Valve stem Oil Controller and
Piston and
Connecting Rod .......... 6A1-3 Valve Spring ..................... 6A1-38
Crankshaft and Bearing .............. 6A1-3 Cylinder Head (SOHC) ............... 6A1-42
Oil Pump .......................... 6A1-3 Cylinder Head (DOHC) ............... 6A1-46
Engine Lubrication . . . . . . . . . . . . . . . . . . 6A 1-3 Oil Pan ............................ 6A 1-50
On-Vehicle Service . . . . . . . . . . . . . . . . . . 6A1-4 Oil Pump .......................... 6A 1-52
Cylinder Head Cover LH (SOHC) ....... 6A1-4 Oil Pump Oil seal ................... 6A 1-53
Cylinder Head Cover RH (SOHC) ...... 6A1-5 Oil Filter ........................... 6A 1-54
Cylinder Head Cover (DOHC) . . . . . . . . . 6A 1-6 Oil Cooler .......................... 6A 1-55
Common Chamber Duct (DOHC) ...... 6A1-8 Piston, Piston Rings and Connecting Rod . 6A 1-56
Common Chamber (SOHC) ........... 6A1-10 Crankshaft and Main Bearings ........ 6A1-57
Common Chamber (DOHC) ........... 6A1-12 Rear Oil Seal ....................... 6A1-60
Intake Manifold (SOHC) .............. 6A1-14 Engine Assembly .................... 6A1-61
Intake Manifold (DOHC) ............. 6A1-16 Main Data and Specification ........... 6A1-63
LH Exhaust Manifold . . . . . . . . . . . . . . . . 6A 1-18 General Specification ................ 6A 1-63
RH Exhaust Manifold ................ 6A1-19 Torque Specification ................ 6A1-64
Timing Belt ........................ 6A1-20 Special Tools ........................ 6A1-69

6A 1-2 ENGINE (V6 3.2L DOHC AND SOHC)
GENERAL DESCRIPTION
SOHC
DOHC
Fig. 6A1-1
•

CYLINDER BLOCK
The cylinder block is made of aluminum die-cast
casting
for 75° V-type six cylinders. It has a rear plate
integrated structure and employs a deep skirt. The
cylinder liner is cast and the liner inner diameter and
crankshaft
journal diameter are classified into grades.
The crankshaft is supported by four bearings
of which
width is different between No.2, No.3 and No.1, No.4;
the
width of No.3 bearing on the body side is different
in order
to support the thrust bearing. The bearing cap
is made
of nodular cast iron and each bearing cap uses
four bolts and two side bolts.
CYLINDER HEAD
The cylinder head, made of aluminum alloy casting
employs a pent-roof type combustion chamber with a
spark
plug in the center.
The intake and exhaust
valves are placed in V-type
design. The ports are cross-flow type.
VALVE TRAIN
SOHC: The camshafts on both banks are driven by a
timing
belt to operate the valves via rocker arm.
No
further valve clearance adjustment is
required, due
to the Hydraulic lash adjuster
attachedtotherockerarm.
DOHC: Intake camshaft on the both sides of banks are
driven through a
timing belt, while exhaust
camshaft are driven by the both sides
of intake
camshaft through chains.
The driven camshafts open and
close valves
through swing arms.
Valve clearance is automatically adjusted by
means
of HLA built in the cylinder head.
INTAKE MANIFOLD
SOHC: The intake manifold system is composed ofthe
aluminum cast common chamber and intake
manifold attached with six fuel injectors.
DOHC: The intake manifold system is composed of the
aluminum cast common chamber duct having
the induction
control valve, common chamber
and intake
manifold attached with six fuel
injectors.
EXHAUST MANIFOLD
The exhaust manifold is made of nodular cast iron.
PISTONS AND CONNECTING RODS
Aluminum pistons are used after selecting the grade
that meets the cylinder bore diameter. Each piston has
two compression rings and one oil ring. The piston pin
made
of chromium steel is offset 1 mm toward the
thrust side, and the thrust pressure
of piston to the
cylinder wall varies gradually as the piston travels. The
connecting rods are made
of forged steel. The
connecting rod bearings are graded
for correct size
selection.
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-3
CRANKSHAFT AND BEARINGS
The crankshaft is made of Ductile cast-iron.Pins and
journals are graded for correct size selection for their
bearing.
OIL PUMP
The trochoid-type oil pump is driven by crankshaft.
Operation and service procedures are described in this
section.
ENGINE LUBRICATION
The oil discharged by a trochoid-type oil pump driven
by the crankshaft is fed through full-flow oil filter and
engine
coolant cooled oil cooler up to the oil gallery
provided under the crankshaft bearing cap. The oil is
then
led to the crankshaft journals and cylinder head.
The crank pins are
lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft journals on the connecting
rod
for piston cleaning. The oil pan flange is sealed with
liquid packing only; do not deform or damage the
flange surface during removal or installation.

6A1-4 ENGINE (V6 3.2L DOHC AND SOHC)
ON-VEHICLE SERVICE
CYLINDER HEAD COVER LH (SOHC)
1••1 REMOVAL
Preparation: • Battery ground cable
1. Ignition wire
• Disconnect from spark plug side.
2. Positive Crankcase Ventilation hose and
Vacuum hose
• Disconnect from common chamber.
• Disconnect vacuum hose from throttle body.
3. Engine harness bracket
• Remove fixing bolts on cylinder head cover.
4. Exhaust Gas Recirculation pipe and valve
• Remove fixing bolts on cylinder head cover.
• Remove two fixing bolts on exhaust manifold.
•
Remove two valve fixing bolts on common
chamber.
5. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
I••IINST ALLA TION
5. Cylinder head cover
• Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-12078
/
~
!8;
4
or equivalent) of bead diameter 2-3 mm at four
places of arched area of camshaft brackets on
front and rear sides. (Fig. 6A 1-3)
Application points (Front and rear)
Fig. 6A1-3
• Tighten bolts to the specified torque.
1~1 Torque N·m (lb·in) 8 (69)
•

4. Exhaust Gas Recirculation pipe and valve
• Tighten each fixing bolt to the specified torque.
Valve fixing bolt
1«1 Torque N·m (lb·in) 8 (69)
CYLINDER HEAD COVER RH (SOHC)
1
2
4
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-5
Exhaust manifold fixing bolt
1«1 Torque N·m (lb·ft) I 28 (21)
3. Engine harness bracket
2. Positive Crankcase
Ventilation hose and
Vacuum hose
1. Ignition wire
3
Removal steps
1. Common chamber 2. Ventilation hose
3. Fuel hose
4. Engine hanger
5. Heater pipe
6.
Cylinder head cover
Installation steps
To install, follow the removal
steps in the reverse order.
Fig. 6A1-4
EJ REMOVAL
Preparation: • Battery ground cable
1. Common chamber
• See "Removal and installation of common
chamber".
2. Ventilation hose
• Disconnect from cylinder head cover.
3. Fuel hose
• Disconnect feed and return hoses from fuel
pipes.
• Remove two fuel hose fixing bolts on the
cylinder head cover.
4. Engine hanger
• Remove heat protector on exhaust manifold.
•
Remove bolts and nuts that secure the hanger
to the exhaust manifold and cylinder head.
5. Heater pipe
• Remove heater pipe fixing bolts from the
bracket.
6. Cylinder head cover
• Remove 11 fixing bolts, then the cylinder head
cover.
I•+IINSTALLATION
6. Cylinder head cover
• Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-12078
or equivalent) of bead diameter 2-3 mm to four
places of arched area of camshaft brackets on
front and rear sides. (Fig.6A 1-5)
• Tighten bolts to the specified torque.
1«1 Torque N·m (lb·in) 8 (69)

6A1-6 ENGINE (V6 3.2L DOHC AND SOHC)
Application points (Front and rear)
Fig. 6A1-5
5. Heater pipe
• Tighten bolts to the specified torque.
~~~ Torque N·m (lb·ft) I 21 (15)
CYLINDER HEAD COVER (DOHC)
2
4
4. Engine hanger
• Tighten bolts and nuts to the specified torque.
Bolt
~~~ Torque N·m (lb·ft) 21 (15)
Nut
~~~ Torque N·m (lb·ft) 57 (42)
3. Fuel hose
2. Ventilation hose
1. Common chamber
• See "Removal and installation of common
chamber".
.J
Removal steps
1. Common chamber duct 2. Common chamber
3. Fuel hose
4. Cylinder head cover
Installation steps To install, follow the removal step in the reverse order.
Fig. 6A1-6
•

E) REMOVAL
Preparation: Battery ground
1. Common chamber duct
• Refer to "Common chamber removal and
installation" in this section.
2. Common chamber
• Refer to "Common chamber removal and
installation" in this section.
3. Fuel hose
• Disconnect feed and return hose from fuel pipe.
4. Cylinder head cover
I••IINSTALLATION
4. Cylinder head cover
• Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-12078
or equivalent) of bead diameter 2-3 mm to four
places of arched area of camshaft brackets on
front and rear sides. (Fig. 6A 1-7)
• Tighten bolts to the specified torque.
1«1 Torque N·m (lb·in) 8 (69)
Application points (Front and rear)
Fig. 6A1-7
3. Fuel hose
• Connect the fuel hose as shown in the Fig. 6A 1-
8.
ENGINE (V6 3.2L DOHC AND SOHC) 6A 1-7
2-7 mm (0.08-0.28 in.)
r-
0-3 mm (0-0.12 in.)
·~(t)yCIIp
Fig. 6A1-8
2. Common chamber
• Refer to "Common chamber removal and
installation" in this section.
1. Common chamber duct
• Refer to "Common chamber removal and
installation" in this section.