Remove engine ISUZU TROOPER 1998 Service Repair Manual

ENGINE MECHANICAL 6A – 41
CYLINDER HEAD
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Legend
(1) Glow Plug
(2) Plate
(3) Cylinder Head Bolt
(4) Cylinder Head
NOTE:
•During disassembly, be sure that the valve train
components are kept together and identified so that
they can be re-installed in their original locations.
•Before removing the cylinder head from the engine
and before disassembling the valve mechanism, do
a compression test and note the results.
DISASSEMBLY
1. Injector Assy
2. Glow Plug and Glow Plug Connector
3. Cylinder Head Assembly
•Refer to “Cylinder Head Gasket”
CLEAN
•Cylinder head
Carefully remove all varnish, soot and carbon on
the bare metal. Do not use a motorized wire brush
on any gasket sealing surface.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
1. Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause;
–Improper installation
–Loosen or warped cylinder head
–Insufficient torque on head bolts
–Warped cylinder block surface

6A – 44 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove air cleaner and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Remove PCV hose.
7. Remove EGR vacuum hose.
8. Disconnect harness connector around the cylinder
head.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out fan belt.
12. Remove heat protector and remove valve
assembly.
13. Remove water hose and oil pipe from turbocharger.
14. Remove turbocharger assembly.
15. Remove water hose between thermostat and
radiator.
16. Remove cylinder head noise insulator cover.
NOTE: Do not make damage to the harness.
17. Remove high pressure pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner and remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove water pipe between cylinder head and
water pump.
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe.
26. Remove intake manifold assembly.
27. Disconnect glow plug wiring and remove glow plug.
28. Remove cylinder head cover.
29. Drain oil from oil rail.
30. Disconnect injector harness connector.
31. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
32. Disconnect injector harness assembly.
33. Remove injector clamp.
34. Remove injector spacer (If equipped.).
35. Remove injector assembly.
36. Remove oil rail assembly.
37. Remove camshaft carrier.
38. Remove cylinder head assembly.
39. Remove cylinder gasket.
INSTALLATION
1. Install cylinder head gasket with top mark up.
NOTE: Determine cylinder head gasket grade by
measuring projection of piston head.2. Selection cylinder head gasket.
1) Measure the piston head projection by dial
gauge.
2) Measure the projection of piston head at the
nearest possible point to the cylinder bore.
3) Obtain the largest measurement from among all
cylinders.
4) Determine cylinder head gasket grade by
maximum value of measuring projection of
piston head.
Legend
(1) Top Mark
(2) Grade Mark
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6A – 48 ENGINE MECHANICAL
DISASSEMBLY
1. Injector clamp
2. Injector assembly
3. Oil rail assembly
4. Camshaft bracket
5. Camshaft
6. Oil seal
7. Plug
NOTE: Before starting disassembly above, drain oil
from oil rail to prevent oil from entering the cylinder.
REASSEMBLY
1. Camshaft
1) Before reassembling the camshaft to the
camshaft carrier, align the holes between the
main gear and the sub gear on the intake side of
the camshaft gear with a special tool.
2) Set lock pin to gear holes from sub gear side.
Camshaft Gear Tool: 5-8840-2591-0
Legend
(1) Locking pin
(2) Special tool
3) Apply engine oil to the camshaft gear tooth.
4) Apply engine oil to the journal on the camshaft
carrier.
5) Align the timing mark on the intake and exhaust
camshaft gear and put on the camshaft carrier.Legend
(1) Locking pin
(2) Intake side camshaft gear
(3) Exhaust side camshaft gear
6) Apply liquid gasket (TB1207B or equivalent) to
No. 1 camshaft bracket matching surface.
7) Set No. 1 to No. 5 camshaft bracket on camshaft
carrier.
8) Temporarily tighten bracket bolts B and C.
Temporal Torque: 20 N·m (2.0 kg·m/14.5 lb ft)
9) Put gasket on the cylinder head.
10) Install camshaft carrier onto the cylinder head
and tighten bolts to specified torque.
Torque: A; 22 N·m (2.2 kg·m/15.9 lb ft)
B; 38 N·m (3.9 kg·m/28.2 lb ft)
C; 22 N·m (2.2 kg·m/15.9 lb ft)
D; 38 N·m (3.9 kg·m/28.2 lb ft)
•Remove locking pin.
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CC
D
B
CC
B
CC
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CC
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AAAA
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6A – 50 ENGINE MECHANICAL
NOTE: Do not allow the camshaft to rotate.
6) Remove the camshaft bracket and measure the
plastigauge width and determine the oil
clearance. If the oil clearance exceeds the
specified limit, replace the camshaft carrier
and/or camshaft.
Oil clearance.
Standard: 0.040 – 0.082 mm (0.0016 – 0.0032 in)
Limit: 0.12 mm (0.0047 in)
7) Clean the plastigauge from the camshaft bracket
and camshaft carrier.
5. Camshaft thrust clearance.
1) Clean the camshaft, camshaft bracket and
camshaft carrier.
2) Put camshaft carrier on the cylinder head.
3) Put camshaft on the camshaft carrier.
4) Put plastigauge on the camshaft journal.5) Install camshaft bracket to original position and
tighten bolts to specified torque in the numerical
order shown in the illustration.
Torque: A; 22 N·m (2.2 kg·m/15.9 lb ft)
B; 38 N·m (3.9 kg·m/28.2 lb ft)
C; 22 N·m (2.2 kg·m/15.9 lb ft)
D; 38 N·m (3.9 kg·m/28.2 lb ft)
6) Use a dial indicator to measure the camshaft
thrust clearance. If the camshaft thrust
clearance exceeds the specified limit, replace
the camshaft carrier and/or camshaft.
Camshaft thrust clearance
Standard: 0.1 mm (0.0002 in)
Limit: 0.2 mm (0.0078 in)
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CC
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CC
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A AA A A A
AAAA
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6A – 52 ENGINE MECHANICAL
TIMING GEAR
REMOVAL
1. Loosen fixing bolt for generator and remove
generator assembly.
2. Remove fixing nuts, then remove cooling fan
assembly and fan pulley.
3. Remove crankshaft damper pulley.
4. Belt cover
1) Disconnect harness connector of CMP
(camshaft position) sensor.
2) Remove CMP sensor.
3) Remove belt cover.
5. Loosen belt tensioner to remove timing belt.
6. Remove camshaft pulley.
7. Remove high pressure oil pump pulley.
8. Remove front plate.
9. Remove vacuum pump.
10. Remove power steering pump.
11. Remove gear cover assembly.
12. Idle gear A.
1) Set two bolts to sub gear of idle gear A and turn
it to align the tooth of idle gear A then lock them
by bolt as show in the illustration.
2) Remove idle gear A fixing bolts.
3) Remove idle gear A.Legend
(1) Sub-Gear
(2) Main Gear
(3) Bar
(4) Locking Bolt
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Legend
(1) Idle Gear A
(2) High Pressure Oil Pump Gear
(3) Vacuum Pump Gear
(4) Power Steering Pump Gear(5) Balance Gear LH
(6) Idle Gear C
(7) Crankshaft Gear
(8) Balance Gear RH
(9) Idle Gear B
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ENGINE MECHANICAL 6A – 53
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear A
(4) Idle Gear A Shaft
(5) Align Mark
(6) Crankshaft Gear
(7) O-Ring
13. Idle gear C
1) Use the special tool on idle gear C, turning the
sub gear to align the teeth, then set lock pin.
2) Remove idle gear C fixing bolt then remove the
idle gear C with flange.
Camshaft Gear Tool : 5-8840-2591-0
Legend
(1) Lock pin
(2) Camshaft Gear ToolLegend
(1) Bolt
(2) Retainer
(3) Idle Gear C
(4) Idle Gear C Shaft
(5) Align Mark
(6) Align Mark
(7) Idle Gear A
(8) Balance Shaft Gear LH
(9) Timing Mark
14. Idle gear B
1) Loosen idle gear B fixing bolt to remove idle
gear B with flange.
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear B
(4) Idle Gear B Shaft
(5) Align Mark
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6A – 54 ENGINE MECHANICAL
15. High pressure oil pump
1) Remove oil pump gear fixing bolt then remove
oil pump.
Legend
(1) O-Ring
(2) High Pressure Oil Pump Gear
(3) Bolt
(4) Timing Mark
16. Remove balance shaft gear LH. and RH.
17. Remove crankshaft gear.
INSTALLATION
1. Crankshaft gear
1) Force key into the crankshaft and insert
crankshaft gear with the crankshaft gear key
groove set on the key.Legend
(1) Crankshaft Gear Installer
(2) Crankshaft Gear
2. Balance shaft gear
1) Install the balance shaft gear RH to balance
shaft, tighten center bolt to the specified torque.
Torque : 32 N·m (3.2 kg·m/23 lb ft)
2) Install thrust plate for balance shaft LH before
installing the balance shaft gear LH.
Torque : 25 N·m (2.5 kg·m/18 lb ft)
3) Install balance shaft gear LH to balance shaft,
tighten center bolt to the specified torque.
Torque : 32 N·m (3.2 kg·m/23 lb ft)
Legend
(1) Center Bolt
(2) Plate
(3) Balance Shaft Gear RH
(4) Timing Mark
4
GEAR:O/PUMP
IDLE GEAR A
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6A – 56 ENGINE MECHANICAL
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear B
(4) Idle Gear B Shaft
(5) Align Mark
6. High pressure oil pump
1) Install O-ring on the high pressure oil pump.
2) Install the high pressure oil pump to the timing
gear case, tighten the nut to the specified
torque.
Torque: 20 N·m (2.0 kg·m/14.5 lb ft)
NOTE: Be sure to set O-ring completely.
Legend
(1) O-ring (large)
(2) High pressure oil pump
(3) Nut
(4) O-ring (small)7. High pressure oil pump
1) Install O-ring on the oil pump shaft with grease
and install the gear with the idle gear A timing
mark set at the oil pump gear timing mark.
2) Tighten center bolt to the specified torque.
Torque: 75 N·m (7.6 kg·m / 55 lb ft)
NOTE: Be sure to align timing marks with each other.
Legend
(1) O-ring
(2) High Pressure Oil Pump Gear
(3) Center Bolt
(4) Timing Mark
8. Remove lock from idle gear.
1) Remove lock bolt from idle gear A and remove
lock pin from idle gear C.
9. Timing gear case assembly
1) Clean fixing surface of timing gear case.
2) Install the gasket on the idle gear rear side end.
3) Apply liquid gasket to the timing gear case fitting
surface.
NOTE: Be sure to apply liquid gasket evenly.
4) Install timing gear case and tighten bolts to the
specified torque.
Torque: 20 N·m (2.0 kg·m / 14.5 lb ft)
NOTE: Must install within 5 minutes after applying liquid
gasket.
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GEAR:O/PUMP
IDLE GEAR A
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6A – 60 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drivebelt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
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Legend
(1) Adjuster
(2) Tappet
(3) Split Collar
(4) Spring Seat Upper
(5) Valve Spring(6) Spring Seat Lower
(7) Valve Stem Seal
(8) Valve Guide
(9) Valve Seat
(10) Valve

ENGINE MECHANICAL 6A – 61
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe from rear of cylinder head.
26. Remove intake manifold assembly.
27. Disconnect glow plug harness and remove glow
plug.
28. Remove cylinder head cover.
29. Remove injector harness connector.
30. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
31. Remove injector harness assembly.
32. Remove injector clamp.
33. Remove injector is fixed bolts.
34. Remove injector assembly.
35. Remove oil rail.
36. Remove camshaft carrier assembly with camshaft.
37. Remove cylinder head assembly.
38. Disassemble valve spring according to the following
method.
1) Use valve spring compressor then remove split
collars.
2) Valve spring compressor: 5-8840-2441-0
NOTE: Put removed valve spring in order of cylinder
number.
39. Valve stem seal.
1) Use a screwdriver or pliers to remove valve
stem seal.
NOTE: Do not reuse removed valve stem seal.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Valve spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Free height
1) Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit.
Standard: 45.85 mm (1.8051in)
Limit: 43.9 mm (1.7283 in)
2. Squareness
1) Measure the valve spring squareness with a
steel square.
2) Replace the valve springs if the measured value
exceeds the specified limit.
Limit: 1.6 mm (0.063 in)
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