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
         3.2.2.15. 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>> Pistons and rods

3.2.2.29. Pistons and rods

GENERAL INFORMATION

Arrangement of piston rings (on 4-cylinder engines)

1 – lower compression ring

2 – an orientation tag of the piston (it is directed forward)

3 – top compression ring

4 – top radial dilator of an oil scraper ring

5 – axial dilator

6 – lower radial dilator of an oil scraper ring

Arrangement of piston rings (on 6-cylinder engines)

And – joints of oil scraper rings
In – a joint of the lower compression ring
With – dredging on the piston
D – joints of oil scraper rings
Е – joint of the top compression ring

Arrangement of piston rings (on diesel engines)

 
1 – tags of the manufacturer
2 – lower compression ring
3 – joints of oil scraper rings
4 – joints of oil scraper rings
5 – top compression ring

It is recommended to remove pistons with rods only for their replacement. If pistons are removed, then surely it is necessary to replace piston fingers. At survey of the piston pay attention to existence of chips, cracks or traces of the increased wear. The removed rings should be stored so that at assembly to establish on former places. Check the main sizes of the piston a micrometer. At installation of rings pay attention that the tag of NPR or TORAHS was turned up. On each piston there is an orientation tag which is put in the top part of an opening under a finger. At assembly this tag has to be turned forward. Besides, on a body and on a cover of a rod number of the cylinder in which this piston was installed is beaten out. Before removal of a rod and cover apply number of the corresponding cylinder on these details to facilitate assembly.

Removal of a fillet on the cylinder


Prevention

This procedure is easily feasible when the engine is removed from the car. If it is possible to remove the pallet without removal of the engine, then a fillet it is possible to remove also without removal of the engine.


PERFORMANCE ORDER
1. Remove a head of cylinders, the soaking-up and final collectors, the oil pallet and the oil pump (see subsection 3.2.2.7, subsection 3.2.2.8, subsection 3.2.2.14.1, subsection 3.2.2.17 and subsection 3.2.2.18).
2. Install the engine on the stand. The fillet is removed to get the piston assembled with a rod from the cylinder. Take away the piston in the lower situation, cover with rags and remove a fillet with development, without allowing excessive removal of material.
3. Uncover conrod bearings and bearings.
4. Dress pieces of a rubber hose on bolts of rods.
5. Get the piston assembled with a rod through the top part of the block of cylinders.
Prevention

It is forbidden to make efforts at extraction of the piston.

If not to remove a fillet, then at installation of new rings their breakage is possible.


Orientation of pistons

Orientation tag on the piston

1 – an orientation tag which has to be turned towards a forward part of the engine.

Tags of mutual orientation of a rod and cover of the conrod bearing

Almost on all pistons there are orientation dredging or tags. If tags are absent, then before removal of pistons they should be put. Pistons are installed so that orientation tags were turned forward.

Cleaning and check of a state

PERFORMANCE ORDER
1. Remove rings by means of an expander.
2. Clear flutes of rings the old broken piston ring.
3. Wash out the piston in solvent and remove a deposit and resinous deposits. It is forbidden to wash out pistons in acids, alkalis and to brush their wire.
4. Examine the piston. At detection of strong damages replace the piston.
5. Measure the internal diameter of the cylinder in two directions (parallel to and perpendicular to a piston finger), at distance of 64,0 mm from the demountable plane with a head. Then measure diameter of a skirt of the piston parallel to and perpendicular to a piston finger.
6. The difference of diameters of the cylinder and piston is equal to a gap between the piston and the cylinder. If the gap meets standard, or it is slightly less (after boring of cylinders), then it is possible to be limited only to a honningovaniye of cylinders.
7. If the gap is higher than norm, then it is necessary to pick up pistons from normal dimensional group, but with a diameter corresponding to the top limit.
8. If it is impossible, then pistons should be replaced repair, cylinders to otkhonningovat or chisel.
9. If conicity exceeds 0,127 mm, and ovality – 0,076 mm, then it is recommended to chisel cylinders under the next repair size and to replace pistons and rings of the corresponding repair size.
10. After all measurements sort pistons.

Prevention

Boring and honningovaniye of cylinders should be carried out in a workshop of car service. At insignificant wear of the cylinder it is allowed to execute a honningovaniye directly on the car, without removal of the engine, however, if boring and a honningovaniye under the repair size is required, then the engine should be removed and completely to sort.


Piston fingers

Installation of a piston finger and lock ring on diesel engines

At full dismantling it is necessary to handle the pistons cast from soft aluminum alloy especially carefully. It is forbidden to subject them to blows and to clamp in a vice. On a part of engines of the considered modifications the finger is pressed in the piston, and on a rod has floating landing. The vypressovka and a press fitting of a finger in such engines requires the special equipment therefore it is expedient to perform this work in workshops of car service.


Prevention

On 4-cylinder engines of all modifications an orientation tag on the piston (which has to be turned on the car course forward) and a company brand of ISUZU on a rod have to be turned into one party.


Measurement technique of the pistons removed from the car

Measurement of diameter of a skirt of the piston

For measurement of conicity of the piston diameter on an axis of a piston finger and is measured in the skirt basis.

Diameter of the piston is measured at distance of 19,0 mm below an axis of a piston finger.

These measurements are necessary for check of a gap between the piston and the cylinder for definition of further suitability of the piston.

PERFORMANCE ORDER
1. Measure the internal diameter of the cylinder by a telescopic nutromer.
2. Measure diameter of the piston. For check of diameter of the piston and its conicity it is necessary to take a piston finger.
3. The gap between the piston and the cylinder is defined as a difference of diameters of the cylinder and piston.
4. Compare a gap to tabular data.
5. When checking conicity of the piston it is necessary to measure its diameter in the skirt basis.
6. If the gap does not meet standard, then cylinders should be chiseled, and to replace pistons repair.

Selection of new pistons

In the spare part pistons of the repair size which diameter is increased concerning diameter of the standard piston with a step of 0,25 mm (0,25, 0,75, 1,00 and 1,5 mm) are delivered.

The cylinder is chiseled and honningutsya on the picked-up pistons. Number of the corresponding cylinder is applied on pistons.

Check of a gap in a joint of rings

Check of a gap in a joint of a piston ring


PERFORMANCE ORDER
1. Oil the internal surface of the cylinder for the engine.
2. Push a ring the piston bottom on depth of 25,0 mm of rather demountable plane under a head of cylinders and measure a gap by the probe.
3. If the gap is less than norm, then the ring should be filed a file.
4. If the gap is higher than norm, then replace a ring.

Installation of rings and check of a gap between a wall of a flute and a ring

Installation of the piston by means of the device for compression of rings

Check of a gap between a wall of a flute and a ring

1 – piston ring

2 – probe

3 – flute


PERFORMANCE ORDER
1. Check purity of oil channels in piston flutes.
2. Establish a ring and the probe check a gap between a wall of a flute and a ring. The probe has to be located between a ring and the lower wall of a flute.
3. If the gap is higher than norms, then replace the piston as at installation of new rings their increased wear and the raised oil consumption is possible. In the spare part piston rings only of one thickness are delivered.
4. Compression rings are established only by means of an expander, otherwise their breakage is possible. Place joints of new rings according to an illustration on their packing.