Isuzu Trooper (1998-2002 year). Manual - part 559

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

012RW073

011RW043

ENGINE MECHANICAL 6A – 45

Cylinder head gasket and piston projection

CAUTION:

•

The projection of each piston should be 0.333
mm or more and less than 0.483 mm.

•

Maximum difference in projection between
pistons should be less than 0.1 mm.

•

If the piston projection is without standard,
reassemble the engine all over again.

3. Install cylinder head assembly, tighten bolts by

angular tightening method.

Torque:

1st step;

49 N·m (5.0 kg·m/36 lb ft)

2nd step; 60°
3rd step; 60°

CAUTION: The cylinder head bolts cannot be
reused.

4. Install camshaft carrier assembly.

Refer to “Camshaft” in this manual.

5. Install oil rail and injector assembly.

Refer to “Oil rail and injector” in this manual.

6. Install injector harness to connect harness

connector.

Note: Apply liquid gasket (TB 1207B or equivalent) to
the rubber seal of the camshaft end, injector harness
gasket area and No. 1 camshaft bracket. Refer to the
Cylinder head cover.

7. Install cylinder head cover.

Torque: 9 N·m (0.9 kg·m/78 lb in)

8. Install glow plug to tighten specified torque.

Torque: 15 N·m (1.5 kg·m/11 lb ft) and connect

glow plug harness.

9. Install intake manifold.

Torque: 20 N·m (2.0 kg·m/14 lb ft)
10. Install fuel return pipe.
11. Install fuel pipe in between fuel pump and intake

manifold.

12. Install water pipe in between cylinder head and

water pump.
Tighten flange bolt to the specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)
13. Install front plate.

Torque: 20 N·m (2.0 kg·m/14 lb ft)
14. Install camshaft pulley, tighten with angular

tightening method.

1st step 40 N·m (4.1 kg·m/30 lb ft)
2nd step 60°

NOTE: Apply engine oil to camshaft pulley bolt.

15. Align timing mark oil pump pulley and camshaft

pulley to front plate then put the timing belt and
tighten tensioner bolt.

Torque: 20 N·m (2.0 kg·m/14 lb ft) for M8

50 N·m (5.1 kg·m/37 lb ft)

16. Install CMP sensor bracket.
17. Install timing belt cover.

Torque: 9 N·m (0.9 kg·m/78 lb in)
18. Fill with about 300 cc of engine oil from the high

pressure oil pipe installing port of oil rail using an oil
filler.
If assembled without filling the oil rail with oil, the
time for engine start will be longer.

19. Immediately install high pressure oil pipe to tighten

with specified torque.

Torque: 78 N·m (8.0 kg·m/58 lb ft)
20. Install cylinder head noise insulator cover.

Torque: 9 N·m (0.9 kg·m/78 lb in)

Grade A

Grade B

Grade C

011RW042

Grade

Piston projection

Gasket

thickness

more 0.333 to less 0.383

1.35

more 0.383 to less 0.433

1.40

more 0.433 to less 0.483

1.45

6A – 46 ENGINE MECHANICAL

Legend

(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt, Stud and Rubber Mounting

21. Install water hose between thermostat and radiator.
22. Install turbocharger assembly to exhaust manifold.

Torque: 27 N·m (2.8 kg·m/20 lb ft)
23. Install water hose and oil pipe for turbocharger.

24. Install exhaust valve assembly and heat protector.

Torque: 57 N·m (5.8 kg·m/42 lb ft) for valve

Torque: 9 N·m (0.9 kg·m/78 lb in) for heat protector

25. Install generator assembly.

Torque: 40 N·m (4.1 kg·m/30 lb ft) for ACG bracket

Torque: 40 N·m (4.1 kg·m/30 lb ft) between ACG and

bracket

Torque: 20 N·m (2.0 kg·m/14 lb ft) between ACG

and adjuster plate

26. Fix the A/C compressor bracket and install A/C

compressor.

Torque: 46 N·m (4.7 kg·m/34 lb ft) for A/C bracket

Torque: 20 N·m (2.0 kg·m/14 lb ft) for belt tensioner
27. Reconnect harness connector around cylinder

head.

28. Connect EGR vacuum hose.
29. Install oil level gauge guide assembly.

Tighten nuts lower portion and tighten bolt.

Torque: 20 N·m (2.0 kg·m/14 lb ft)
30. Install intercooler assembly.

Refer to “Intercooler” in this manual.

31. Install air duct between air cleaner and

turbocharger.

32. Fill engine coolant.
33. Reconnect battery.

For Europe

025R200007

For Europe

025R200006

010R200006

ENGINE MECHANICAL 6A – 47

CAMSHAFT

With
spacer type

Without
spacer type

012R200004

Legend

(1)

Nut and Washer

(2)

Injector Clamp

(3)

Nut

(4)

Bolt

(5)

Oil Rail Assembly

(6)

Spacer (If equipped) and Bolt

(7)

Injector Assembly

(8)

Camshaft

(9)

Camshaft Carrier

(10)

Plug

(11)

Oil Seal

(12)

Camshaft Bracket

(13)

Gasket

(14)

Gasket

Content .. 557 558 559 560 ..