1995 ISUZU TROOPER Workshop Manual

GENERAL ENGINE MECHANICAL 6A-37
CYLINDER BLOCK
1.,!•1 DISASSEMBL V
1. Cylinder head assembly
2. Cylinder head gasket
3. Oil pan
4. Oil pipe and rubber ring
5. Oil strainer and rubber ring
6. Oil pump assembly
7. Crankcase side bolts
8. Oil gallery
9. Piston and connecting rod assembly
1 0. Flywheel
11. Rear oil seal assembly
12. Main bearing cap
13. Crankshaft
14.
Cylinder block
Fig. 6A-108
Disassembly steps
1. Cylinder head assembly
2. Cylinder head gasket
3. Oil pan
4. Oil pipe and rubber ring
5.
Oil strainer and rubber ring
6. Oil pump assembly
7. Crankcase side bolts
8.
Oil gallery
9. Piston and connecting rod
assembly
10. Flywheel
11. Rear oil seal assembly
12. Main bearing cap
13. Crankshaft
14.
Cylinder block
Reassembly steps
To reassemble, follow the disassembly steps in the reverse order.
(1!] INSPECTION AND REPAIR
1. Remove the gasket and any other material
adhering to the upper surface of the cylinder
block.
m Be very careful not to allow any material to
LQI accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal
retainer, and oil pan installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block.
If
necessary, use a flaw detector to perform a dye
penetrate and
hydraulic (or air pressure) test.
If cracking or other damage is discovered, the
cylinder block must either be repaired or
replaced.

L
6A-38 GENERAL ENGINE MECHANICAL
I @.I Flatness
1. Using a straight-edge and feeler gauge, check
that the upper surface of the cylinder block is not
warped (Fig.
6A-109)
\fl CAUTION:
VI Be very careful not to allow any material to
accidentally drop into the upper surface of the
cylinder block.
Be very careful not to seratch the upper surface of
the cylinder block.
2. The cylinder block must be reground or replaced
if the warpage exceeds the limit.
Warpage Limit 0.15
(0.0059)
mm(in)
Maximum
repairable limit
0.15
(0.0059)
Fig. 6A-1 09
CYLINDER BORE
l'fil Use a cylinder gauge to measure the cylinder
1..!:.1 bore diameter in both the axial and thrust
directions.
Each measurement
should be made at six points
(Fig. 6A-110).
\fl CAUTION:
VI Be very careful not to allow any material to
accidentally drop into the upper surface of the
cylinder block.
Be very careful not to scratch the upper surface of
the cylinder block.
Cylinder
bore
inside diameter Limit
93.530 (3.6823) mm(in)
lfthe measurement
exceed the specified limit, the
cylinder block must be replaced.
j -A] I B
c
--~ lED ED
A : 12 mm (0.47 in.)
B : 48 mm (1.89 in.)
C : 95 mm (3.74 in.)
mm(in)
Grade Diameter
A 93.400-93.41
0 (3.6772-3.6776)
B 93.411-93.420 (3.6776-3.6779)
c 93.421-93.430 (3.6780-3.6783)
Fig.
6A-110
NOTE:
For information on piston diameter, please refer to the
section
"Inspection of the Piston and Connecting Rod
Assembly" in this manual.
•
The "Grade" mark is stamped at the position
illustrated in Fig. 6A-111.
Grade mark
-+lllf++---+-+1-'--"--tt.:-H----:!+--~=rt--r;,T#;T ;1 ~+=+=J ~~~
Fig. 6A-111
•

1,.!.,1 REASSEMBLY
14. Cylinder block
13. Crankshaft
1•1• Install the main bearings to the cylinder block
and the main bearing caps (Fig. 6A-112).
• Be sure that they are positioned correctly.
•
Apply new engine oil to the upper and lower
main bearing faces.
• Carefully mount the crankshaft.
1~·1 .• Apply engine oil to the thrust washer.
Assemble the thrust washer to the No. 3
bearing
journal. The oil grooves must face the
crankshaft (Fig. 6A-113).
r--!::"
11-1
~
Upper and lower
#1,4
Upper
#2,3
Fig. 6A-112
Fig. 6A-113
12. Crankshaft bearing cap
Lower
#2,3
D • Apply engine oil to the threads and the seating
L:J faces of the bolts.
I• I• Install bearing caps in the order shown with the
No.1 as the front most bearing cap (Fig. 6A-114)
• Semitighten all of bolts. Finally, tighten all the
bolts to specification in the order shown (Fig.
6A-115)
Torque
N·m (lb·ft) 39 (29)
After the final tightening, check to see that the
crankshaft rotates
smoothly.
GENERAL ENGINE MECHANICAL &A-39
Forward
Fig. 6A-114
Fig. 6A-115
11. Rear oil seal assembly
• Tighten all the bolts.
~~~ Torque N·m (lb·ft)
1 0. Flywheel
18 (13)
r:l]1) Thoroughly clean and remove the oil from the
threads
of crankshaft.
2) Remove the oil from the crankshaft and
flywheel mounting faces.
3) Mount the flywheel on the crankshaft and then
install the washer.
4) Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown (Fig. 6A-116).
~~~ Torque N·m (lb·ft) 54 (40)
NOTE:
•
Do not reuse the bolts.
•
Do not apply oil or thread lock to the bolts.

6A-40 GENERAL ENGINE MECHANICAL
Fig. 6A-116
9. Piston and connecting rod assembly.
Cl • Apply engine oil to the cylinder bores, the
L:J connecting rod bearings and the crankshaft
pins.
NOTE:
Do not apply engine oil to the bearing back
faces and the connecting rod bearing fitting
surfaces.
• Check to see that the piston ring end gaps are
correctly positioned (Fig. 6A-117).
Oil ring--~~~=!==:::;:,.::~~--No.1 side rail Compression (Lower) ring
Front mark
No. 2--~~~~i::::::=~~;(.,.--Oil ring Compression side rail ring (Upper)
Fig. 6A-117
• Insert the piston/connecting rod assemblies
into each cylinder with the piston ring com­
pressor.
• The front marks must be facing the front of the
engine (Fig. 6A-118).
8.
Front mark
Front mark
Fig. 6A-118
Oil gallery
• Tighten the bolts in 2 steps in the order shown
(Fig. 6A-119).
1~1 _________ 1s_t,s_te~p ________ +-_2_n_d_S_t_e_p ___
7.
N·m (lb·ftl 29 (22) ss· -ss·
Crankcase side bolts (Fig. &A-119)
• Tighten crankcase bolts in sequence shown in
the
illustration.
I~I __ T_o_r~qu_e __ N_·_m __ (lb_·ft_)~ ______ 3_9_(2_9_l ____ _
Q : Oil gallery fixing bolts 0 : Crankcase bolts
Fig. 6A-119
6. Oil pump assembly
• Refer to Section 6A 1 "Oil pump installation".
5. Oil strainer and rubber ring
4.
Oil pipe and rubber ring
•