1998 ISUZU TROOPER Service Repair Manual

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Page 1825 of 3573

ISUZU TROOPER 1998 Service Repair Manual 6A– 92 ENGINE MECHANICAL
CYLINDER BLOCK
1
15
14
13
8
11
16
17
10
9
72
12
3
465
18
012RW023
Legend
(1) Cylinder Head
(2) Cylinder Head Gasket
(3) Flywheel
(4) Cylinder Block Rear Plate (A/T)
Flywhee

Page 1826 of 3573

ISUZU TROOPER 1998 Service Repair Manual ENGINE MECHANICAL 6A– 93
DISASSEMBLY
1. Cylinder Head Assembly
Refer to “Cylinder Head” in this manual.
2. Cylinder Head Gasket.
3. Flywheel
4. Cylinder Block Rear Plate (A/T), or Flywheel
housi

Page 1827 of 3573

ISUZU TROOPER 1998 Service Repair Manual 6A– 94 ENGINE MECHANICAL
Cylinder Bore Measurement
1. Use a cylinder gauge to measure the cylinder bore
measuring direction for thrust and radial at
measuring points.
Legend
Measuring Point 1; 20 mm

6A– 94 ENGINE MECHANICAL
Cylinder Bore Measurement
1. Use a cylinder gauge to measure the cylinder bore
measuring direction for thrust and radial at
measuring points.
Legend
Measuring Point 1; 20 mm
2; 90 mm
3; 160 mm
2. Select the right piston grade by the averaged
cylinder bore measurement (maximum and
minimum value eliminated).
Cylinder bore diameter mm(in)
Grade mark Standard
A 95.421 – 95.430 (3.7567 – 3.7571)
B 95.431 – 95.440 (3.7571 – 3.7575)
C 95.441 – 95.450 (3.7575 – 3.7579)
3. If measured values exceed the limit, replace or
adjust the cylinder block honing or boring.
Limit 95.950 mm (3.7776 in)
4. Boring of the cylinder bore is allowed until it is
0.5 mm (0.0197 in) diameter and oversized piston
is available as a service part.
Boring Cylinder Block
1. Use an oversized piston on the basis of above
mentioned cylinder using the largest inside
diameter.
2. Measure the piston outside diameter at right angles
with piston pin at a piston grade measuring point
69.75 mm (2.7461 in) from piston top surface and
calculate a inside diameter for cylinder boring.
3. Calculation of cylinder bore boring.
D + C – H (mm)
D; Outside diameter piston (mm)
C; Clearance between Cylinder bore and piston
0.092 – 0.110 mm (0.0036 – 0.0043 in)
H; Honing allowance
Less than 0.03 mm (0.0012 in)
The oversize pistons are available three grades.
4. Honing the cylinder bore after boring.
5. Measure cylinder bore after honing.
Difference between each cylinder bore
Less than 0.02 mm (0.0008 in)
Cylinder bore and piston grade (After boring) mm(in)
GradeOversize Piston Bore
Mark
Outside Diameter Diameter
A95.820 – 95.829 95.921 – 95.930
(3.7724 – 3.7728) (3.7764 – 3.7768)
B95.830 – 95.839 95.931 – 95.940
(3.7728 – 3.7732) (3.7768 – 3.7772)
C95.840 – 95.849 95.941 – 95.950
(3.7732 – 3.7736 ) (3.7772 – 3.7776)
REASSEMBLY
1. Cylinder Block
2. Piston Cooling Oil Pipe
1) Fix the cooling jet pipes with knock pins on the
cylinder block.
2) Install the oil pipe for piston cooling in the
cylinder block, tightening a relief valve (1) and
four joint bolts (2) to the specified torque.
If oil jet pipe is forcibly assembled, the end of oil
jet may bend. It could make it impossible to
supply oil to the piston cooling hole, sometimes
causing piston seizure.
Sufficient care should be taken to pipe assembly
work.
321
012RW117

Page 1828 of 3573

ISUZU TROOPER 1998 Service Repair Manual ENGINE MECHANICAL 6A– 95
Oil pipe fixing bolts
M8: 20 N·m (2.0 kg·m/14 lb ft)
M6: 8 N·m (0.8 kg·m/69 lb in)
Relief valve fixing bolts : 30 N·m (3.1 kg·m/22 lb ft)
CAUTION: After installing the

Page 1829 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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 Blo

Page 1830 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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 cov

Page 1831 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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

Page 1832 of 3573

ISUZU TROOPER 1998 Service Repair Manual ENGINE MECHANICAL 6A– 99
OIL COOLER
For Europe1
2050R200001
Legend
(1) Oil Cooler Assembly
(2) Oil Filter Cartridge
OIL FILTER CARTRIDGE
REMOVAL
1. Place a receptacle beneath the oil filter to conta

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