Isuzu Trooper (1998-2002 year). Manual - part 572

6A – 96 ENGINE MECHANICAL

NOTE: Check to see that the crankshaft turns
smoothly by rotating it manually.

4. Piston Assembly

1) Refer to “Piston and connecting rod” in this

manual.

5. Cylinder Block Side Cover Right and Left
6. Balance Shaft Right.

Apply new engine oil to the balance shaft (right) and
insert it into cylinder block.

7. Timing Gear Case

1) Cut out the liquid gasket forced out from

between the contact surface of cylinder block
and crankshaft.

2) Apply liquid gasket (TB1207B or equivalent) to

the fitting surface of the cylinder block and
crankcase.

3) Install timing gear case with gasket to cylinder

block and tighten to specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

8. Crankshaft Gear

Force key into crankshaft and force in crankshaft
gear along the key groove using a special tool (1)
with the crank gear (2) timing mark facing outside.

9. Install timing gear align the timing mark on each

timing gear.
For alignment of timing marks refer to “Timing
Gear” in this manual.

NOTE: Remove the locking bolt or pin from idle gear A
and idle gear C.

10. Assembling the gear case cover.

1) Install the oil seal on the oil pump assembly

before installing the gear case cover.

2) Apply liquid gasket to timing gear case.

NOTE: Be sure to apply liquid gasket evenly.

8

4

1

5

9

6

10

2

3

7

012RW027

012RW064

1

2

2

012RW066

2

2~2.5mm

2~2.5mm

Apply liquid gasket around inside 
of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

ENGINE MECHANICAL 6A – 97

11. Use the special tool to install the crankshaft front oil

seal to timing gear case.
Front Oil Seal Installer: 5-8840-2061-0

1) Check fit-of the oil seal and gear case cover at

the front end.

Standard: 0.5 – 2.5 mm (0.0197 – 0.0984 in)

NOTE: Apply engine oil to oil seal lip before installation
of the seal.

12. Install the oil pan assembly to original position and

tighten to specified torque.

Torque: 22 N·m (2.2 kg·m/16 lb ft)
13. Crankshaft Rear Oil Seal

1) Tighten the adapter to the crankshaft rear end

with 2 bolts.

2) Insert the oil seal into the adapter.

NOTE: Apply oil to oil seal lip.

3) Insert the sleeve into the adapter and tighten it

with a bolt (M12 x 1.75L = 70) until the adapter
hits the sleeve.

4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the dimension of

the oil seal outside end and crankshaft end.

Standard Dimension = 12.5 ± 0.3 mm

Oil Seal Installer: 5-8840-2359-0

14. Cylinder Block Rear Plate (A/T Model)

1) Tighten the cylinder block rear plate fixing bolts

to the specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)
15. Flywheel Housing (M/T Model)

1) Install flywheel housing aligned with the dowel

pin on the cylinder block.

2) Tighten the flywheel housing fixing bolts to the

specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)
16. Flywheel

1) Refer to “Crankshaft” in this manual.

17. Cylinder Head Assembly

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

015RW074

12.5 + 0.3

–

012RW067

6A – 98 ENGINE MECHANICAL

OIL PUMP ASSEMBLY

2

1

5

6

3

4

012RW097

Legend

(1)

Flywheel

(2)

Rear Plate (A/T)

(3)

First Oil Pump Assembly

(4)

Second Oil Pump Assembly

(5)

O-Ring (For first oil pump)

(6)

O-Ring (For second oil pump)

REMOVAL

1. Disconnect battery ground cable
2. Lift up car
3. Drain engine oil

NOTE: Install drain plug with new gasket.

4. Flywheel
5. Rear Plate (A/T) or Flywheel Housing (M/T)
6. First Oil Pump Assembly and Second Oil Pump

Assembly
1) Remove oil pump assembly from cylinder block

and crankcase.

INSTALLATION

1. First oil pump assembly

1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the

balance shaft RH.

3) Apply engine oil to pump gear, install pump gear

to rear end of cylinder block with specified
torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

2. Second oil pump assembly

1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the

balance shaft LH.

3) Apply engine oil to pump gear, install pump gear

to rear end of crank case with specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

3. Install rear plate (A/T) or flywheel housing (M/T)

Torque: 97 N·m (9.9 kg·m/72 lb ft)

4. Install flywheel

1) Apply engine oil to bolt and tighten with 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°

ENGINE MECHANICAL 6A – 99

OIL COOLER

For Europe

1

2

050R200001

Legend

(1)

Oil Cooler Assembly

(2)

Oil Filter Cartridge

OIL FILTER CARTRIDGE

REMOVAL

1. Place a receptacle beneath the oil filter to contain

the drained oil.

2. Remove the oil filter cartridge using filter wrench.

Filter wrench : 5-8840-0203-0

INSTALLATION

1, Lightly apply oil to the O-ring of oil filter cartridge.
2. Turn the new oil filter cartridge by hand until the

sealing face is fitted against the O-ring.

3. Use the filter wrench to turn the oil filter an

additional one and 1/8 turns.

4. Start the engine and check for oil leakage from oil

filter.