1998 ISUZU TROOPER Service Repair Manual

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Page 1809 of 3573

ISUZU TROOPER 1998 Service Repair Manual 6A– 76 ENGINE MECHANICAL
7) Apply plastigage to the crankshaft journal unit as
shown in the illustration.
8) Install the main bearing caps. Apply engine oil to
the bolt threads and the seats. Tighte

Page 1810 of 3573

ISUZU TROOPER 1998 Service Repair Manual ENGINE MECHANICAL 6A– 77
Crankshaft inspection
Inspect the surface of the crankshaft journals and crank
pins for excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear
a

ENGINE MECHANICAL 6A– 77
Crankshaft inspection
Inspect the surface of the crankshaft journals and crank
pins for excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear
and damage.
Inspect the oil ports for obstructions.
Crankshaft tufftriding inspection
1. Use an organic cleaner to thoroughly clean the
crankshaft. There must be no traces of on the
surfaces to be inspected.
2. Prepare a 5 – 10% solution of ammonium cupric
chloride (dissolved in distilled water).
3. Use a syringe to apply the solution to the surface to
be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from running.
NOTE: Do not allow the solution to come in contact with
the oil ports and their surrounding area (Approximately
10 mm).Judgment
1. Wait for thirty or forty seconds.
If there is no discoloration after thirty or forty
seconds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.
2. Steam clean the crankshaft surface immediately
after completing the test.
NOTE: The ammonium cupric chloride solution is highly
corrosive. Because of this, it is imperative that the
surfaces being tested be cleaned immediately after
completing the test.
CRANKSHAFT BEARING SECTION
When installing new crankshaft bearings, refer to the
selection table below.
Select and install the new crankshaft bearings, paying
close attention to the cylinder body journal hole
diameter grade mark and the crankshaft journal
diameter grade mark.
NOTE: Although all upper journal bearings (cylinder
body side) have oil grooves and holes, all lower
bearings (bearing cap side) have no groove and hole.
Play close attention to the distinction during the
installation procedure.
012RW045
The portion to be tested
must be held horizontally
so as not to let the test
solution flow.
The sliding surface
of the pin
or journal.Test liquid should
not be applied to
the area around the
oil port.
Approximately
10mm
F06MV020
012RW038

Page 1811 of 3573

ISUZU TROOPER 1998 Service Repair Manual 6A– 78 ENGINE MECHANICAL
Crankshaft Bearing Bore Grade Mark Position
Crankshaft bearing bore grade marks
1or 2are
stamped on the rear right hand side of the cylinder
body.
Example:
No. 1 Bearing No

Page 1812 of 3573

ISUZU TROOPER 1998 Service Repair Manual ENGINE MECHANICAL 6A– 79
Main Bearing Crankshaft
Bore Diameter mm(in) Main Journal Diameter mm(in)Crankshaft Oil Clearance
Grade Inside Diameter Grade Outside DiameterBearing mm(in)
1 or - 69.927

Page 1813 of 3573

ISUZU TROOPER 1998 Service Repair Manual 6A– 80 ENGINE MECHANICAL
3. Piston and Connecting Rod Assembly
1) Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins
and each piston ring and piston.
2) Alig

6A– 80 ENGINE MECHANICAL
3. Piston and Connecting Rod Assembly
1) Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins
and each piston ring and piston.
2) Align the front mark (2) of piston and front mark
(3) of connecting rod then assemble them.
3) The N mark of the piston ring is faced toward the
top, check to see that the piston ring end gap is
correctly positioned.
Legend
(1) 1st piston ring end gap
(2) 2nd piston ring end gap
(3) Oil ring end gap4) Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Piston Ring Compressor: 5-8840-9018-0
5) Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
6) Apply engine oil to the threads and seating faces
of the nuts.
7) Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications.
1st step: 29 N·m (3.0 kg·m/22 lb ft)
2nd step: 45°– 60°
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly
4. Piston Cooling Oil Pipe
If the piston cooling oil pipe is forcibly assembled,
the end of the oil jet may bend. It could make it
impossible to supply oil to the piston cooling holes,
which will sometimes cause piston seizure.
Sufficient care should be taken to pipe assembly
work.
1) Tighten the bolt and oil jet plug to the specified
torque.
Torque:
M6: 8 N·m (0.8 kg·m/6 lb ft)
M8: 20 N·m (2.0 kg·m/14.5 lb ft)
Oiling Jet Plug: 30 N·m (3.1 kg·m/22 lb ft)
5. Crank case
1) Refer to “Crank case” in this manual.
6. Apply liquid gasket (TB-1207C or equivalent) to
retainer then install it to rear end of cylinder block
within 5 minutes.
7. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear and
section with 2 bolts.
2) Insert the oil seal into the peripheral section of
the adapter.
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) Check the dimension of the oil seal setting from
rear end of crankshaft.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-0
2
3
1
015RW051
3
1
2
015RW083

Page 1814 of 3573

ISUZU TROOPER 1998 Service Repair Manual ENGINE MECHANICAL 6A– 81
8. Cylinder Block Rear Plate (A/T)
Align the rear plate with the cylinder block dowel
pins.
Tighten the rear plate to the specified torque.
Torque: 97 N·m (9.9 kg·m/72 lb

Page 1815 of 3573

ISUZU TROOPER 1998 Service Repair Manual 6A– 82 ENGINE MECHANICAL
2) Apply liquid gasket (TB1207B or equivalent)
between the cylinder block and the crankcase
fitting surfaces.
3) Install the timing gear case to the cylinder body.
4) Tighte

Page 1816 of 3573

ISUZU TROOPER 1998 Service Repair Manual 15. Crankshaft Front Oil Seal
1) Set oil seal with special tool.
2) Install front oil seal to timing gear case cover.
Crankshaft Front Oil Seal Installer: 5-8840-2061-0
3) Remove special tool and chec

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