Isuzu Trooper (1998-2002 year). Manual - part 565

6A – 68 ENGINE MECHANICAL

3. Determine the thickness of the adjuster as follows.

1) Measure the thickness of the removed adjuster

with a micrometer.

2) Calculate the thickness of a new adjuster.

Calculation
TA: Thickness of new adjuster
M:  Valve clearance measurement.
TO: Thickness of the removed adjuster
For intake side:

TA=TO+(M–0.15) mm

For exhaust side:

TA=TO+(M–0.25) mm

Select a new adjuster whose thickness is as
close to the estimated value as possible.

4. Install oil rail and tighten it temporarily.
5. Install injector assembly.

NOTE:

1) Do not forget to insert the O-ring between injector

and oil rail.

2) Install the injector to the same position as before

removal.

6. Install the injector fixing bolts and temporarily

tighten.

7. Install the injector clamp and tighten temporarily.
8. Tighten injector fixing bolts to the specified torque.

Torque: 6.5 N·m (0.7 kg·m / 61 lb in)

9. Tighten injector clamp nut to the specified torque

with special method.

Torque: 30 N·m (3.1 kg·m /22 lb ft) then loosen one
turn and tighten again to specified torque.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)
10. Tighten oil rail to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)
11. Install injector harness and reconnect connector.
12. Install cylinder head cover.

Refer to”Cylinder Head” in this manual.

13. Fill with about 300cc of engine oil at the high

pressure oil pipe installation port on the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.

14. Immediately install high pressure oil pipe to tighten

with specified torque.

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

Refer to “Cylinder Head” in this manual.

ENGINE MECHANICAL 6A – 69

OIL RAIL AND INJECTOR

REMOVAL

Prior to removal, be sure to confirm and record the
group code of the injector installed using Tech2.

1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler.

Refer to “Intercooler” in this manual.

4. Remove PCV hose and pipe.
5. Remove cylinder head noise insulator cover.
6. Remove high pressure oil pipe.

CAUTION:

1) Sleeve nut should be loosened with cloth tied

around it to prevent oil from spurting due to the
remaining pressure.

2) The high pressure pipe should be disconnected

with a cloth tied around the intake manifold
glow plug to prevent oil from flowing out of the
oil rail.

7. Loosen eye bolt of fuel pipe at fuel pump side.

NOTE: Cloth should be put around the loosened eye
bolt to prevent fuel from flowing out.

8. Remove fuel return hose at chassis side.
9. Remove PCV hose to cylinder head cover.

10. Remove cylinder head cover.
11. Drain the oil from oil rail assembly.
12. Record the identification marking of injector for

each cylinder which is indicated on the upper
portion of injector.
There are nine kinds of identification marking
available, one alphabet letter and one numeral
letter.
In case three kinds of markings are given, one
alphabet letter (sometimes printed) and one
numeral letter, top priority is given to the one
alphabet letter and one numeral letter.

1

6

2

7

3

5

4

With
spacer type

Without
spacer type

012R200005

Legend

(1)

Injector Clamp

(2)

Injector Assembly

(3)

Oil Rail Assembly

(4)

Camshaft Bracket

(5)

Camshaft

(6)

O-Ring

(7)

Drain Plug

6A – 70 ENGINE MECHANICAL

(For example)
If you find identification marking “A”, “RA” and “2”
on the injector, you can use injector grade “A”. (The
“RA” is sometimes printed, but can be ignored)

Legend

(1) Part Number
(2) Two Alphabet Letter
(3) Serial Number
(4) Bar Code
(5) One Alphabet Letter
(6) One Numeral Letter

13. Remove harness connector from each injector.
14. Loosen nuts and bolts for oil rail.
15. Remove injector fixing bolts.
16. Remove injector clamp.
17. Remove injector assembly.

NOTE: Do not drop O-ring 

INSTALLATION

1. Install oil rail, tighten temporarily
2. Install injector assembly.

NOTE: Do not forget to install O-ring between injector
and oil rail.

3. Apply oil and install injector fixing bolts, tighten

temporarily.

4. Apply oil and install injector clamp, tighten nut

temporarily.

5. Tighten injector bolts to the specified torque.

Torque: 7 N·m (0.7 kg·m / 61 lb in)
6. Tighten injector clamp nut to the specified torque

with special method.

Torque: 30 N·m (3.1 kg·m / 22 lb ft) then loose a
time again tighten as following torque.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)
7. Tighten oil rail to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)
8. Install injector harness assembly, reconnect

harness connecter to injector.

9. Record the identification marking of injector for

each cylinder that is indicated on the upper portion
of injector.

Legend

(1) Part Number
(2) Two Alphabet Letter
(3) Serial Number
(4) Bar Code
(5) One Alphabet Letter
(6) One Numeral Letter

10. Install cylinder head assembly.

Refer to “Cylinder Head” in this manual.

11. Fill with about 300cc of engine oil from the high

pressure oil pipe at the high pressure oil pipe
installation port on the oil rail using an oil filler.
If assembled without filling the oil rail with oil, the

1

4

3

2

6

5

055RW021-1

1

4

3

2

6

5

055RW021-1

Identification

One Alphabet One Numeral

Marking

Letter

Letter

Grade

A

1

A

A

2

A

3

B

1

B

B

2

B

3

C

1

C

C

2

C

3

ENGINE MECHANICAL 6A – 71

time for engine starting will be longer.

12. Immediately install high pressure oil pipe and

tighten to specified torque.

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

Refer to “Cylinder Head” in this manual.

14. Install intercooler assembly.

Refer to “Intercooler” in this manual.

15. Install air cleaner cover and air duct.
16. Use TECH2 to rewrite injector data to ECM.

For rewriting method refer to section “Data
Programming in Case of ECM Change” of 6E 4JX1
engine driveability and emissions in this manual.

NOTE:

1) On completion of servicing, bleed air from the

engine inside fuel passage by means of the priming
pump. (The priming pump should be operated more
times than in the case of conventional engines.)

2) As air is in the oil rail, it takes more time to start the

engine. Rough idling may occur while the air is
being bled completely after starting the engine, but
it does not indicate trouble.
The air will be bled and normal engine status will be
reached while the vehicle is driven for about 5 km
or engine is operated for about 5 minutes at 1500 to
2000 rpm.

3) The injector spare part will be provided for group

number B1, B2 and B3 only.