Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1676

6A-2 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

PAGE

Camshaft Housing, Check for Plance Surface ......................................................... 6A-44

Cylinder Head, Removal and Installation.................................................................. 6A-44

Cylinder Head, Disassemble and Assemble............................................................. 6A-47

Valve, Grind ................................................................................................................. 6A-49

Valve Seating, Mill ...................................................................................................... 6A-50

Cylinder Head, Overhaul ............................................................................................ 6A-50

Flywheel....................................................................................................................... 6A-51

Starter Ring Gear(Manual Transmission) ................................................................. 6A-52

Seal Ring, Crankshaft................................................................................................. 6A-53

Seal Ring, Crankshaft Rear........................................................................................ 6A-53

Gasket, Oil Pan ........................................................................................................... 6A-54

OPERATIONS ON CRANK DRIVE................................................................................... 6A-56

Con-Rod Bearing ........................................................................................................ 6A-56

Piston with Con-Rod................................................................................................... 6A-56

Con-Rod....................................................................................................................... 6A-57

Pistion Rings ............................................................................................................... 6A-58

OPERATIONS ON REMOVED ENGINE........................................................................... 6A-60

Crankshaft ................................................................................................................... 6A-60

Bearing Free Play Measurement ............................................................................... 6A-62

Plastigage Method ...................................................................................................... 6A-62

Micrometer and gauge method.................................................................................. 6A-63

Bypass Valve............................................................................................................... 6A-64

Oil Filter ....................................................................................................................... 6A-64

Oil Pump ...................................................................................................................... 6A-64

Oil Pump Safety Valve ................................................................................................ 6A-65

Oil Pump(Overhaul) .................................................................................................... 6A-65

OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-66

Cylinder Head Safety Valve........................................................................................ 6A-66

OPERATIONS ON COOLING SYSYTEM......................................................................... 6A-68

Cooling System, Check for Leakes ........................................................................... 6A-68

Cooling System, Fill Up and Bleed............................................................................ 6A-68

Refill Coolant............................................................................................................... 6A-69

Ignition Timing, Check ............................................................................................... 6A-69

ENGINE EXTERNAL PARTS ........................................................................................... 6A-70

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-3

PAGE

Radiator ....................................................................................................................... 6A-70

Thermostat .................................................................................................................. 6A-70

Water Pump................................................................................................................. 6A-71

Coating sealing surfaces with Silicone Grease ....................................................... 6A-71

Alternator..................................................................................................................... 6A-71

Starter .......................................................................................................................... 6A-71

V-belt Tension of Alternator....................................................................................... 6A-72

FULE INJECTION SYSTEM ............................................................................................. 6A-73

Map Sensor ................................................................................................................. 6A-73

Pressure Regulator..................................................................................................... 6A-73

ECM (Engine Control Module) ................................................................................... 6A-74

ECT............................................................................................................................... 6A-75

Idle Air Control(IAC) Valve ......................................................................................... 6A-75

Ignition Coil ................................................................................................................. 6A-75

Crank Position Sensor ............................................................................................... 6A-75

FUEL INJECTOR .............................................................................................................. 6A-76

Knock Sensor.............................................................................................................. 6A-76

Oxygen Sensor............................................................................................................ 6A-77

Throttle Valve Position Sensor.................................................................................. 6A-77

Acclelerator Pedal and Cable .................................................................................... 6A-77

Air Cleaner Filter ......................................................................................................... 6A-78

Spark Plug Thread ...................................................................................................... 6A-79

TECHNICAL DATA ........................................................................................................... 6A-80

Recommended Troque Values .................................................................................. 6A-91

SPECIAL SERVICE TOOL ............................................................................................... 6A-92

6A-4 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

GENERAL DESCRIPTION

Engine Cleanliness And Care

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that
are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine
parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper
cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered
standard shop practice even if not specifically stated.

!

A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate
the surfaces on initial operation.

!

Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal
bearings are removed for service, they should be retained in order.

!

At the time of installation, they should be installed in the same locations and with the same mating surfaced as
when removed.

!

Battery cables should be disconnected before any major work is performed on the engine. Failure to
disconnect cables may result in damage to wire harness or other electrical parts.

!

The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft
pulley.

General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage and

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-5

contributing to reliable engine performance:

!

When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the
oil pick up unit.

!

The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical
terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.

!

Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect
against accidental entrance of foreign material into the cylinder which could cause extensive damage when
the engine is started.

Cylinder Block

The cylinder block is made of cast iron. The crankshaft is supported by five bearings. The bearing cap is made of
nodular cast iron.

Cylinder Head

The cylinder head is made of aluminum alloy casting with a spark plug in the center.

Valve Train

Valve system is a single over head camshaft.
The valves clearance adjustment are hydraulic.
Hydraulic valve lifter adjustment, no adjustment necessary.

Intake Manifold

The intake manifold is made of aluminum alloy.

Exhaust Manifold

The exhaust manifold is made of high Si-Mo nodular iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made of cast hardened steel. The connecting rod bearings are
made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.

Crankshaft and Bearings

The crank shaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.