Isuzu Trooper (1998-2002 year). Manual - part 566

6A – 72 ENGINE MECHANICAL

CRANK CASE

REMOVAL

1. Drain engine oil.
2. Remove transmission assembly.
3. Remove crankshaft damper pulley.
4. Remove timing belt cover, timing belt, pulley and

front plate.

5. Remove timing gear case cover.
6. Remove timing gears.

NOTE: Do not forget to set lock bolt for idle gear A and
lock pin for idle gear C.

7. Remove timing gear case.
8. Remove oil level gauge guide assembly.
9. Remove flywheel assembly.

CAUTION:

1) The flywheel heavy; be careful not to drop it.

2) Be careful no to let it slip because the hexagon

of the bolt is thin.

10. Remove rear plate (for A/T) or flywheel housing (for

MT).

11. Remove retainer.

NOTE:

1) Be careful not to damage the oil seal; it can be

reused.

2) Inspect installation portion for distortion and flow on

the slinger; also inspect for flow on the oil seal lip.

3) If there is some flow oil seal/slinger, replace a set.

12. Remove bolts from thrust plate of balance shaft LH

then remove balance shaft.

13. Loosen crank case fixing bolts.
14. Use seal cutter to take off the liquid gasket.

Seal cutter: 5-8840-2153-0

15. Remove crank case assembly.

CAUTION:
Do not give shock to crank case for prevention take
off applied vibration insulation material on the
crank case.

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Legend

(1)

Crank Case

(2)

Oil Pan

(3)

Drain Plug

ENGINE MECHANICAL 6A – 73

INSTALLATION

1. Install relief valve (if it was removed).

Torque: 30 N·m (3.1 kg·m / 22 lb ft)

2. Apply oil and insert O-ring to strainer, install strainer

and tighten to specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

3. Apply liquid gasket (TB1207B or equivalent) to

surface of oil pan and tighten bolt to the specified
torque.

Torque: 22 N·m (2.2 kg·m / 16 lb ft)

4. Apply engine oil to the balance shaft (left) and insert

it into crank case.

NOTE:

•

Do not damage bearing when inserting the balance
shaft.

•

Make sure it rotates smoothly.

5. Tighten thrust plate of balance shaft LH.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)

6. Set O-ring port of oil gallery on the cylinder block.
7. Apply liquid gasket (TB1207C or equivalent) to

crankcase fixing surface then tighten bolts to the
specified torque.

Torque: 24 N·m (2.4 kg·m / 17 lb ft)

NOTE: Make sure there is no oil, dust or scratches on
the surface coated with liquid gasket and mount within
five minutes of gasket application.

8. Install retainer with oil seal.
9. Install rear plate (A/T) or flywheel housing (MT),

tighten bolt to the specified torque.

Torque: 97 N·m 9.9 kg·m / 72 lb ft)
10. Install flywheel assembly with applied engine oil to

the bolt, tighten the bolt using angular tightening
method.

1st step: 59 N·m (6.0 kg·m / 43 lb ft)
2nd step: 60° to 90°
3rd step: 60° to 90°
11. Install oil level gauge guide assembly.
12. Install timing gear case.

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

Refer to “Timing Gear” in this manual.

14. Remove lock bolt from idle gear A and remove lock

pin from idle gear C.

15. Install timing gear case cover.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)
16. Install oil pump pulley.

Torque: 10 N·m (1.0 kg·m / 87 lb in)
17. Install camshaft pulley tighten bolt with angular

tightening method.

Torque:
1st step: 40 N·m (4.1 kg·m / 30 lb ft)
2nd step: 60° to 90°
18. Install timing belt and belt tensioner.

Refer to “Timing Gear” in this manual.

19. Install crankshaft damper pulley.

Torque: 216 N·m (22 kg·m / 159 lb ft)
20. Fill engine oil.

2~2.5mm

Apply liquid gasket around inside
of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

2~2.5mm

Apply liquid gasket around inside
of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

6A – 74 ENGINE MECHANICAL

CRANKSHAFT

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Legend

(1)

Cylinder Head

(2)

Cylinder Head Gasket

(3)

Flywheel

(4)

Cylinder Block Rear Plate (for A/T) or Flywheel
Housing (for M/T)

(5)

Crankshaft Rear Oil Seal

(6)

Retainer

(7)

Timing Gear Case

(8)

Crankshaft Front Oil Seal

(9)

Timing Gear Case

(10)

Gasket

(11)

Balance Shaft

(12)

Crank Case

(13)

Piston Cooling Oil Pipe

(14)

Main Bearing Cap

(15)

Crankshaft

(16)

Crankshaft Timing Gear

(17)

Piston and Connecting Rod Assembly

(18)

Cylinder Block

ENGINE MECHANICAL 6A – 75

DISASSEMBLY

1. Cylinder Head

1) Refer to “Cylinder head” in this manual.

2. Crankshaft Front Oil Seal

1) Use a plastic hammer and a screwdriver to tap

around the oil seal to free it from the gear case
cover.
Take care not to damage the oil seal fitting
surfaces.

3. Crankshaft Timing Gear
4. Timing Gear Case
5. Flywheel
6. Cylinder Block Rear Plate
7. Crankshaft Rear Oil Seal

1) Use special tool to remove the crankshaft rear

oil seal.
Oil Seal Remover: 5-8840-2360-0

8. Crank Case
9. Piston Cooling Oil Pipe

10. Piston and Connecting Rod Assembly
11. Main Bearing Cap Assembly
12. Crankshaft

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.

1. Crankshaft Thrust clearance

Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified limit,
replace the thrust bearing as a set.

Standard : 0.04 – 0.20 mm (0.0016 – 0.0079 in)
Limit: 0.30 mm (0.0118 in)

2. Main bearing clearance

1) Remove the main bearing caps in the sequence

shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.

2) Remove the crankshaft. Remove the main

bearings.

3) Clean the upper and lower bearings as well as

the crankshaft main journal.

4) Check the bearings for damage or excessive

wear.
The bearings must be replaced as a set if
damage or excessive wear is discovered during
inspection.

5) Set the upper bearings and the thrust washers

to their original positions. Carefully install the
crankshaft.

6) Set the lower bearings to the bearing cap

original position.

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