Isuzu Trooper - Isuzu Trooper
1. Maintenance instruction
2. Maintenance
3. Engines
   3.1. Specifications of the engine and adjusting works
   3.2. Electric equipment and capital repairs of engines
      3.2.1. Electric equipment of engines
      3.2.2. Capital repairs of engines
         3.2.2.1. Technical characteristics
         3.2.2.2. Instructions on service and repair of the engine
         3.2.2.3. Dismantle and installation of the power unit
         3.2.2.4. Cover of a head of cylinders
         3.2.2.5. Yokes and rollers of yokes
         3.2.2.6. Thermostat
         3.2.2.7. The soaking-up collector
         3.2.2.8. Final collector
         3.2.2.9. Turbocompressor
         3.2.2.10. Conditioner
         3.2.2.11. Radiator
         3.2.2.12. The cooling system fan with the drive from the electric motor
         3.2.2.13. Pump of cooling liquid
         3.2.2.14. Head of cylinders
            3.2.2.14.1. Removal and installation
            3.2.2.14.2. Cleaning and check of a state
         3.2.2.15. Valves and springs
         3.2.2.16. Pushers
         3.2.2.17. Oil pallet
         3.2.2.18. Oil pump
         3.2.2.19. Epiploon of a forward cover of a gear belt
         3.2.2.20. Chain of the drive of the camshaft and asterisk of the drive
         3.2.2.21. Forward cover of a gear belt
         3.2.2.22. Epiploon of a bent shaft
         3.2.2.23. Gear belt and natyazhitel
         3.2.2.24. Gear belt and mechanism of a tension
         3.2.2.25. Drive of the gas-distributing mechanism petrol engines
         3.2.2.26. Drive of the gas-distributing mechanism diesel engines
         3.2.2.27. Camshaft
         3.2.2.28. Camshaft bearings
         3.2.2.29. Pistons and rods
         3.2.2.30. Conrod bearings
         3.2.2.31. Assembly of conrod and piston group and installation on the engine
         3.2.2.32. Caps and heater of a case of the engine
         3.2.2.33. Back epiploon of a bent shaft
         3.2.2.34. Bent shaft and radical bearings
         3.2.2.35. Flywheel and gear wreath
   3.3. Diesel engine 2,8 liters
4. System of decrease in toxicity
5. Fuel system
6. Transmission and running gear
7. Suspension bracket and steering
8. Brake system
9. Body
10. Body electric equipment
11. Diagnostics of malfunctions
12. Electrical circuitries





Isuzu Trooper>> Engines>> Electric equipment and capital repairs of engines>> Capital repairs of engines>> Head of cylinders

3.2.2.14. Head of cylinders

3.2.2.14.1. Removal and installation

ENGINES 4ZD1

Removal

PERFORMANCE ORDER
1. Disconnect the battery from weight. Merge cooling liquid.
2. Expose the piston of the 1st cylinder in compression step VMT, having convinced of combination of adjusting tags. Uncover the ignition distributor, put tags of position of the runner concerning the case of the distributor and position of the case of the distributor concerning a head of cylinders. Remove a collar of the distributor and the distributor.
3. Disconnect inlet and final hoses from a radiator.
4. Take off belts of the drive of the generator and conditioner. Remove the fan.
5. Turn off the central bolt of a pulley of a bent shaft and remove a pulley assembled with a nave.
6. Take off a belt of the drive of the air pump and take the pump aside. Remove the conditioner compressor (if it is provided) and take aside. Remove a compressor arm.
7. Remove a pulley of the pump of cooling liquid. Remove the top part of a forward cover, remove the pump.
8. Remove the lower part of a forward cover.
9. Remove a spring. Weaken the top bolt of a roller of a natyazhitel and to the full displace a roller towards the location of the pump of cooling liquid.
10. Take off a gear belt.
11. Uncover a head of cylinders.
12. Remove rollers assembled with yokes and support for what gradually weaken an inhaling of nuts of fastening of support, since the nuts, most remote from the central part.
13. Lift the car, disconnect an exhaust pipe from a final collector. On cars with a turbo-supercharging disconnect an exhaust pipe from a final branch pipe of a turbocompressor and remove a drive cable.
14. Lower the car, disconnect all tubes, hoses, sockets of conducting and a wire of spark plugs.
Prevention

Before a detachment apply identification tags on all hoses.


15. Disconnect draft of the drive of a butterfly valve, on engines with a turbo-supercharging remove all conducting from nozzles and disconnect the fuel highway from a distributive branch pipe.
16. Turn off bolts of a head of cylinders. Turn off gradually, since extreme angular bolts. If the bolt does not give in to an otvorachivaniye, then moisten it with the getting liquid.
17. Together with the assistant remove a head of cylinders assembled with soaking up and final collectors.

Installation

Sequence of an inhaling

and – an order of an inhaling of covers of rollers of yokes: nuts 1–8 tighten with the moment 22 N. of m; nuts 9 and 10 – with m 7 N.' moment.

– the sequence of an inhaling of a head of cylinders on engines 4ZD1


PERFORMANCE ORDER
1. Clear the socket planes on the block of cylinders and on a head. Check a condition of the plane, existence on it deep scratches, or hollows.
2. Clear carvings of bolts of a head of cylinders and in reciprocal openings in the block, otherwise the moment of an inhaling will not correspond to real.
3. Impose new laying of a head on old, check compliance of laying.
4. Install laying and a head of cylinders on the block, turn and tighten bolts of a head of cylinders. Carry out an inhaling in 2 stages: at the 1st stage tighten bolts with m 57 N.' moment, and at the 2nd stage – m 96 N.' moment.
5. Attach draft of the drive of a butterfly valve, on engines with a turbo-supercharging attach all conducting to nozzles and attach the fuel highway to a distributive branch pipe.
6. Attach all tubes, hoses, sockets and high-voltage wires to spark plugs.
7. Lift the car, attach an exhaust pipe to a final collector. On cars with a turbo-supercharging attach an exhaust pipe to a final branch pipe of a turbocompressor and attach a drive cable.
8. Install rollers assembled with yokes and support, tighten nuts in the specified sequence (see rice. Sequence of an inhaling).
9. Put on a gear belt.
10. Dress a spring of a natyazhitel of a belt. Tighten the top bolt of a roller of a natyazhitel.
11. Establish the lower part of a forward cover.
12. Establish a pulley of the pump of cooling liquid, the top part of a forward cover, install the pump.
13. Install the air pump and a belt of the drive. Establish an arm of the compressor of the conditioner and the compressor (if it is provided).
14. Establish a pulley of a bent shaft, wrap the central bolt.
15. Install the generator, put on a conditioner drive belt. Install the fan.
16. Attach inlet and final hoses to a radiator.
17. Install the ignition distributor, fix a distributor collar.
18. Connect the battery to weight. Fill in cooling liquid, be convinced of lack of a leak.

ENGINE 4ZE1

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, following rules. Disconnect the battery from weight. Merge cooling liquid.
2. Take off drive belts from the pump of the hydraulic booster, the air pump, the fan of the cooling system and the compressor of the conditioner (if it is provided).
3. Expose the piston of the 1st cylinder in compression step VMT.
4. Uncover the ignition distributor with high-voltage wires and the ignition distributor.
5. Turn off bolts of fastening of an exhaust pipe to a final collector.
6. Put identification tags and disconnect all electric sockets and vacuum hoses which can interfere with dismantling.
7. Disconnect cooling system hoses, remove a radiator and the fan.
8. Turn off a bolt of a pulley of a bent shaft and remove a pulley.
9. Uncover top and lower a gear belt, a spring and a gear belt.
10. Turn off a bolt of the conducted camshaft gear wheel, remove a gear wheel and the plug.
11. Remove a guide of a gear belt and a forward plate of a head of cylinders.
12. Uncover a head of cylinders and laying.
13. Turn off bolts of a head of cylinders, remove a head and laying.

Installation

Sequence of an inhaling

and – an order of an inhaling of covers of rollers of yokes on engines 4ZE1

– the sequence of an inhaling of a head of cylinders on engines 4ZD1


PERFORMANCE ORDER
1. Establish new laying, a head of cylinders and tighten bolts in the set sequence (see rice. Sequence of an inhaling). Carry out an inhaling in 2 stages: at the 1st stage tighten bolts with m 76 N.' moment, and at the 2nd stage – m 88–108 N.' moment.
2. Establish the conducted camshaft gear wheel.
3. Establish a cover of a head of cylinders, previously having replaced laying.
4. Combine tags on the camshaft and on a forward plate. Make sure that the flute turned up under a spline on a bent shaft is directed to the index on the block of cylinders.
5. Establish a gear belt in the following order: pulley of a bent shaft, pulley of the oil pump, camshaft, roller of a natyazhitel.
6. Establish covers of a gear belt, previously having replaced laying.
7. Establish a pulley of a bent shaft.
8. Establish cooling system hoses, a radiator and the fan.
9. Attach all electric sockets and vacuum hoses.
10. Wrap bolts of fastening of an exhaust pipe to a final collector.
11. Install the ignition distributor, a cover of the distributor and high-voltage wires.
12. Establish belts of the drive of the pump of the hydraulic booster, air pump, fan of the cooling system and compressor of the conditioner (if it is provided).
13. Connect the battery to weight. Fill in cooling liquid.
14. Start the engine, be convinced of lack of a leak.

V6 ENGINES

Order of an inhaling of bolts of a head of cylinders on V6 engines

Left head of cylinders

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, following rules. Disconnect the battery from weight. Merge cooling liquid.
2. Remove the soaking-up collector.
3. Lift the car and establish on supports.
4. Turn off bolts of fastening of an exhaust pipe to a final collector, remove an exhaust pipe and turn off bolts of fastening of a final collector to a head of cylinders.
5. Remove an oil indicator branch pipe.
6. Lower the car.
7. Turn off nuts of yokes, raise a yoke and get bars of pushers. You store details so that at assembly to establish on former places.
8. Turn off bolts of a head of cylinders as it should be the return specified illustrations.
9. Remove a head of cylinders. It is forbidden to hook for removal of a head it the sharp tool.
10. Clear a head.

Installation

PERFORMANCE ORDER
1. Dress on the directing pins new laying so that the inscription "This side up" was turned up. Carefully establish a head of cylinders.
2. Establish bars of pushers, be convinced that bars rested against pushers. Tighten nuts of yokes with m 20–27 N.' moment.
3. Establish the soaking-up collector.
4. Establish an oil indicator.
5. Wrap bolts of fastening of a final collector to a head of cylinders and bolts of fastening of an exhaust pipe to a final collector.
6. Fill in cooling liquid. Start the engine, be convinced of lack of a leak.

Right head of cylinders

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, following rules. Disconnect the battery from weight. Merge cooling liquid.
2. Remove the soaking-up collector.
3. Remove an arm a cruise control, the gate and a hose of the distributor of air.
4. Lift the car and establish on supports.
5. Turn off bolts of fastening of an exhaust pipe to a final collector and nuts of fastening of a final collector to a head of cylinders.
6. Disconnect an exhaust pipe, remove a collector and a thermal guard (if it is provided).
7. Lower the car.
8. Put identification tags and disconnect conducting and vacuum hoses which can interfere with removal of the right head.
9. Turn off nuts of yokes, raise a yoke and get bars of pushers. You store bars of pushers so that at assembly to establish on former places.
10. Turn off bolts of a head of cylinders as it should be the return specified illustrations.
11. Remove a head of cylinders. It is forbidden to hook for removal of a head it the sharp tool.
12. Clear a head.

Installation

PERFORMANCE ORDER
1. Dress on the directing pins new laying so that the inscription "This side up" was turned up. Carefully establish a head of cylinders.
2. Establish bars of pushers, be convinced that bars rested against pushers. Tighten nuts of yokes with m 20–27 N.' moment.
3. Establish the soaking-up collector.
4. Establish a collector of an exhaust pipe, an exhaust pipe and a thermal guard (if it is provided).
5. Wrap bolts of fastening of a final collector to a head of cylinders and nuts of fastening of an exhaust pipe to a final collector.
6. Establish an arm a cruise control, the gate and a hose of the distributor of air.
7. Fill in cooling liquid. Start the engine, be convinced of lack of a leak.

DIESELS C223 I C223T

Sequence of an inhaling

and – the sequence of an inhaling of yokes on the diesel C223 (m 20 N.' moment)

– the sequence of an inhaling of a head of cylinders on the diesel C223

in – the provision of laying of a head of cylinders on the diesel C223

1 – tag of "Top"

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, following rules. Disconnect the battery from weight. Merge cooling liquid.
2. Remove the cooling system fan assembled and a drive belt. Remove the generator and an arm.
3. Remove the top hose of a radiator and a hose(s) of a heater.
4. Remove the air filter and an air duct.
5. Put identification tags and disconnect vacuum hoses and sockets of conducting.
6. Remove the fuel distributor, a collar and the holder of nozzles.
7. Remove spark plugs and the resistive sensor.
8. Uncover a turbocompressor and a turbocompressor.
9. Remove the soaking-up and final collectors.
10. Uncover heads of cylinders, a cover of pushers of valves and a tube of a supply of oil to yokes.
11. Turn off bolts of fastening of yokes to a head of cylinders and remove yokes.
12. Get bars of pushers and you store them so that at assembly to establish on former places.
13. Turn off bolts of a head of cylinders as it should be, the return specified rice. Sequence of an inhaling. Remove a head of cylinders. If the head does not give in to removal, then carefully knock with the rubber hammer and get moving forward.
14. Compare old and new laying of a head of cylinders. Clear demountable surfaces of a head and the block of cylinders.

Installation

PERFORMANCE ORDER
1. Lay new laying so that the inscription "Top" was turned up.
2. Fill a turbocompressor with fresh oil for the engine.
3. Establish a head of cylinders. Oil head bolts for the engine and turn. Tighten bolts in the following order, observing the sequence of an inhaling.
On diesels with a turbocompressor:
      – the 1st stage – 45–54 N. of m;
      – the 2nd stage – to tighten on 120–150 °.
On diesels without turbocompressor:
      – the 1st stage – 54–63 N. of m;
      – the 2nd stage – 74–81 N. of m (new bolts) or 61–69 N. of m (old bolts).
4. Establish bars of pushers, be convinced that bars rested against cams.
5. Establish yokes and tighten bolts with m 14–24 N.' moment. Adjust a gap in valves.
6. Other works on installation are performed upside-down. Replace laying new.
7. Fill in cooling liquid. Connect the battery to weight. Start the engine, be convinced of lack of a leak.