Isuzu Trooper (1998-2002 year). Manual - part 558

6A – 40 ENGINE MECHANICAL

INSTALLATION

1. Install turbocharger assembly to exhaust manifold,

tighten to the specified torque.

Torque : 27 N·m (2.8 kg·m/20 lb ft)

2. Install exhaust adaptor.

Torque : 27 N·m (2.8 kg·m/20 lb ft)

3. Install heat protector.
4. Install water outlet pipe with gasket.

Torque : 20 N·m (2.0 kg·m/14 lb ft)

5. Install turbocharger oil drain pipe.

Torque : 9 N·m (0.9 kg·m/78 lb in)

6. Install oil supply pipe to turbocharger.

1) Fill with 100 cc engine oil at the turbocharger oil

supply hole before installing the oil pipe.

2) Turn the turbocharger by hand to lubricate

turbocharger shaft.

3) Install oil supply pipe with new gasket to the

turbocharger and tighten oil supply pipe bolts to
the specified torque.

Torque : 22 N·m (2.2 kg·m/16 lb ft) for M10

54 N·m (5.5 kg·m/40 lb ft) for M14

7. Install water inlet pipe with new gasket, tighten to

the specified torque.

Torque : 20 N·m (2.0 kg·m/14 lb ft)

8. Install intercooler assembly.

Refer to “Intercooler” in this manual.

9. Install air cleaner cover with air duct, connect both

side hoses.

10. Fill with engine coolant.
11. Install the battery and connect battery cables.

For Europe

025R200007

For Europe

025R200007

For Europe

025R200006

ENGINE MECHANICAL 6A – 41

CYLINDER HEAD

3

4

1

2

012RW096

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 – 42 ENGINE MECHANICAL

2. Cylinder head for cracks, especially between valve

seats and in the exhaust ports.

3. Cylinder head deck for corrosion, sand particles in

head and porosity.

CAUTION: Do not attempt to weld the cylinder
head. Replace it.

4. Cylinder head lower surface for flatness.

Use a straight edge and a feeler gauge to measure
the cylinder head lower surface warpage.
If the measured values exceed the specified limit,
the cylinder head must be replaced.
Cylinder Head Lower Face Warpage:
Standard: 0.075 mm (0.0029 in) or less
Limit: 0.2 mm (0.0079 in)

Cylinder Head Height:
Standard: 95 mm (3.740 in)

5. Water jacket sealing plugs seating surfaces.
6. Use a straight edge and a feeler gauge to measure

the manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit,
the manifold must be replaced.
Exhaust Manifold Warpage:
Standard: 0.05 mm (0.0020 in) or less
Limit: 0.20 mm (0.0079 in)

CAUTION: Do not attempt to weld the cylinder
head. Replace it.

REASSEMBLY

1. Cylinder Head

•

Refer to “Cylinder Head Gasket”.

2. Glow Plug and Glow Plug Connector

•

Tighten glow plugs.

Torque: 15 N·m (1.5 kg·m/11 lb ft)

011RW006

012RW053

ENGINE MECHANICAL 6A – 43

CYLINDER HEAD GASKET

12

13

14

15

8

3

4

5

6

10

11

9

With
spacer type

Without
spacer type

1

7

2

011R200002

Legend

(1)

Cylinder Head Noise Insulator Cover

(2)

Insulator

(3)

Bolt and Gasket

(4)

Oil Seal

(5)

Gasket

(6)

Cylinder Head Cover

(7)

Bolt, Stud and Rubber Mounting

(8)

Injector Clamp

(9)

Oil Rail

(10)

Injector Assembly

(11)

Camshaft Carrier

(12)

Cylinder Head Bolt

(13)

Cylinder Head Assembly

(14)

Cylinder Head Gasket

(15)

Cylinder Block