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
   3.3. Diesel engine 2,8 liters
      3.3.1. Introduction
      3.3.2. Technical characteristics
      3.3.3. Check of a compression
      3.3.4. Top dead point of the piston No. 1 (BMT)
      3.3.5. Gaps of valves
      3.3.6. Cover of a head of cylinders
      3.3.7. Pulley of a bent shaft
      3.3.8. Casings of a gear belt of the drive of the camshaft
      3.3.9. Gear belt of the drive of the camshaft
      3.3.10. Asterisks of a gear belt, natyazhitel and intermediate pulleys
      3.3.11. Yokes and pushers
      3.3.12. Head of the block of cylinders
      3.3.13. Oil case
      3.3.14. Oil pump
      3.3.15. Oil heater
      3.3.16. Epiploons of the camshaft and bent shaft
      3.3.17. Flywheel
      3.3.18. Fastenings of the engine / transmission
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>> Diesel engine 2,8 liters>> Head of the block of cylinders

3.3.12. Head of the block of cylinders

GENERAL INFORMATION

The marks designating thickness of laying of a head of the block of cylinders

And = 1,50 mm

In = 1,55 mm

With = 1,60 mm

Prevention

At removal of a head of the block of cylinders the engine has to be cold. At installation it is necessary to use new bolts for fastening of a head of the block of cylinders.


Removal

PERFORMANCE ORDER
1. Disconnect a wire of the negative plug of the accumulator.
2. Merge cooling liquid from the cooling system (see subsection 2.4.19.2).
3. Do the following operations.
4. Remove a final collector.
5. Weaken nuts of connections and remove the metal tubes of injectors connecting the injecting pump and injectors.
6. Disconnect a tube of return of fuel from an injector.
7. Pick up the metal phone and a branch pipe connecting an intermediate cooler and a casing of a throttle to system of bystry heating.
8. Take off auxiliary driving belts.
9. Remove the pump of system of the hydraulic booster of steering from fastenings and remove it from a head of the block of cylinders. Hydraulic tubes do not need to be disconnected from the pump.
10. On models with the air conditioning system remove the compressor from a fixing arm and remove it from the engine, without disconnecting a tube from the compressor; do not disconnect any tubes of the air conditioning system. Turn off fixing bolts and remove a fixing arm of the compressor from the engine.
11. Remove yokes and pushers.
12. Turn off a fixing nut and disconnect a food wire from a candle of prestarting heating.
13. Weaken fixing collars and disconnect cooling system hoses from a thermostat casing. Also disconnect hoses of an oven and the oil heater from a head of the block of cylinders.
14. Disconnect the connection socket from the switch of the alarm bulb warning about high temperature of cooling liquid which is twirled in a thermostat casing.
15. Check that all corresponding hoses, tubes, wires were, etc. disconnected.
16. In a certain order gradually weaken bolts of fastening of a head of the block of cylinders on a third of a turn for once until all bolts cannot be turned off fingers. Remove all bolts one after another and you will throw out them; at installation it is necessary to use new.
17. Remove a head of the block of cylinders from the block of cylinders. If necessary slightly knock on a head with the wooden hammer to disconnect it from the block of cylinders. Do not hook a head by means of the lever in places of joints. Pay attention to an arrangement of two adjusting pins, remove them and postpone that they were not lost.
18. Remove laying of a head of cylinders. Do not throw out old laying of a head as it to be necessary for identification new.
19. If there is a need, sort and touch a head of cylinders.

Preparation for installation

PERFORMANCE ORDER
1. To carry out installation of a head of cylinders, it is necessary that the joined surfaces of a head and the block of cylinders were ideally pure. Use solid plastic or a wooden scraper for removal of the remains of old laying.
2. Clean also and heads of pistons. Be very careful as it is very easy to damage these surfaces.
3. Be attentive and do not allow hit of the cleaned-off deposit to oil or water canals – it can block supply of lubricant to any component of the engine. Using an adhesive tape and paper, close openings of water and oil channels, and also openings of bolts. To avoid hit of a deposit in a crack between a head of the piston and a wall of the cylinder cover a crack with a small amount of lubricant.
4. After you cleaned all pistons, remove the lubricant and a deposit which got to a crack by means of a small brush and wipe a surface with a pure rag. Wipe in the same way and pistons.
5. Examine the joined surfaces of the block of cylinders and a head on existence of dents, deep scratches and other damages.
6. If damages of surfaces insignificant, then them it is possible to remove with a file, but if damages serious, then processing on the machine can only be the only alternative to full replacement.
7. Check that openings of bolts in the block of cylinders were pure and not filled in with oil. Blot the oil which got to openings of bolts. It is very important that openings of bolts were pure as it is necessary for achievement of the required moment of an inhaling and for prevention of possibility of cracks in the block of cylinders as a result of hydraulic pressure during tightening of bolts.
8. Old fixing bolts of a head of cylinders need to be thrown out regardless of their appearance.
9. If you suspect that the surface of laying of a head of cylinders is deformed, check existence of deformation by means of a ruler.
10. If you suspect that the surface of laying of a head of cylinders is deformed, check existence of deformation by means of a ruler. Laying of necessary thickness is selected by measurement of a ledge of the piston (see rice. The marks designating thickness of laying of a head of the block of cylinders).
11. Turn a bent shaft so that pistons of cylinders No. 1 and No. 4 were in VMT and combine a mark in a pulley of a bent shaft with the index.
12. Check that the bent shaft was correctly established, then install the dial measuring instrument on the block of cylinders so that its probe could go easily between a head of the piston and the surface of the block of cylinders.
13. Establish an arrow of the device on zero when the probe of the device is installed on the surface of laying of the block of cylinders, then accurately carry out the sensor over the piston No. 1 and measure ledges on forward (A-in) and back (C–D) edges.
14. Repeat this procedure with the piston No. 4.
15. Turn a bent shaft on a turn floor (180 °) that pistons No. 2 and No. 3 were installed in VMT. Measure the size of a ledge of pistons No. 2 and No. 3; in total eight measurements have to turn out.
16. Put together all eight sizes and divide the received number into eight to calculate the average size of a ledge of pistons. Pick up the necessary thickness of laying.

Installation

PERFORMANCE ORDER
1. Wipe absolutely joined surfaces of a head of cylinders and the block of cylinders.
2. Check that two adjusting pins were on the places, and put on new laying the block of cylinders. Make sure that laying is established correctly and the mark TOP is on the external surface of laying.
3. Having secured with the help of the assistant, carefully put on a head the block of cylinders.
4. Slightly oil carvings and the lower part of heads of new bolts. Put on washers bolts. Accurately insert bolts into the openings corresponding to them and twirl them fingers.
5. Twist bolts in turn in a certain order. For a start delay all bolts by means of a wrench with restriction on torque until a step 1 (see subsection 3.3.2).
6. After you tightened bolts until an inhaling of a step 1, tighten them in the same order until an inhaling of a step 2. It is recommended to use angular caliber for achievement of accuracy of an inhaling. If you have no such device, make white paint of a mark the bolt heads specifying movement during tightening. Marks can be used to check on what corner the bolt was tightened.
7. At last, tighten all bolts in necessary sequence until an inhaling of a step 3.
8. Insert pushers and establish yokes (see subsection 3.3.11).
9. Adjust gaps of valves and establish a cover of a head of cylinders.
10. Connect a wire to the sensor of temperature of a cooler and to a candle of prestarting heating.
11. Connect hoses to the case of the thermostat and to a head of cylinders, having fixed them by fixing clips.
12. Establish a final collector and fuel tubes of injectors. Connect a tube of return of fuel and establish an air inlet tube.
13. Install the pump of the power steering and (if it is necessary) the compressor of the air conditioner. Put on intermediate driving belts.
14. Fill the engine cooling system with new coolant.
15. Connect a wire of the minus plug of the accumulator, start the engine and check the engine for existence of leaks.

The number of dredging in laying
Laying thickness
One dredging
1,50 mm
Two dredging
1,55 mm
Three dredging
1,60 mm

Average size of a ledge of the piston
The required laying thickness
0,758–0,812 mm
1,3 mm
0,813–0,858 mm
1,4 mm
0,859–0,914 mm
1,5 mm