Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1683

6A-30 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

Adjust

Loosen the fastening bolt of the toothed belt tension roller and
turn the adjustment eccentric in the direction of arrow
(clockwise) until pointer (1) comes to the left stop.
Remove the toothed belt.

Installation

1. Install a new toothed belt while keeping tension side taut.

Adjust

Toothed belt tension - see operation " Toothed Belt Tension".

2.

Install the toothed belt to the cover.

3.

Install the crankshaft pulley while counterholding on the
fastening bolt of toothed belt drive gear.

4.

Install the fan shroud.

5.

Install the fan belt.

6.

Install the V-belt for A/C.

7.

Install the V-belt for power steering.

8.

Install the fan.

9.

Install the belts to the bracket for alternator.

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-31

OPERATIONS ON INSTALLED ENGINE

SEALING OPERATIONS

Gasket, Exhaust Manifold, Cylinder Head

Removal

1.

Remove front exhaust pipe from exhaust manifold.

2.

Remove exhaust manifold heat shield.

3.

Remove exhaust manifold retaining nut.

4.

Remove exhaust manifold from cylinder head.

Clean

Sealing surfaces.

Tighten (Torque)

Exhaust manifold to cylinder head - 22 N

⋅m (2.2 kgf⋅m)

Front exhaust pipe to exhaust manifold - 25 N

⋅m (2.6 kgf⋅m)

Gasket, Intake Manifold, Cylinder Head

Removal

1.

Remove air intake hose.

2.

Remove drive belt for alternator.

3.

Remove bolt clamping bracket for alternator from intake
manifold.

4.

Remove intake manifold from cylinder head.

Clean

Sealing surfaces

Tighten (Torque)

Intake manifold to cylinder head - 22 N

⋅m (2.2 kgf⋅m)

Clamping bracket for alternator to intake manifold - 25 N

⋅m (2.5

kgf

⋅m)

Installation

1.

Install V-belt according to the corresponding operation.

2.

Install air intake hose.

6A-32 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

Seal Ring, Camshaft Housing, Timing Side

Removal

1.

Remove front toothed belt cover toothed belt from
camshaft timing gear according to the corresponding
operation.

2.

Remove camshaft housing cover and camshaft timing
gear.

3.

Remove sealing ring by making hole in middle of ring,
turning in self-tapping screw and edging out.

Installation

1.

Install sealing ring by using 5-8840-0451-0 with camshaft
sprocket bolt and washer.

2.

Install coat seal lips of shaft seal ring slightly.

Seal Ring, Thermostat Housing, Cylinder Head

Removal

1.

Open radiator drain tap and collect coolant.

2.

Remove toothed belt rear cover and toothed belt
according to the corresponding operation.

3.

Remove camshaft housing cover.

4.

Remove camshaft timing gear by counterholding
camshaft with a flat spanner.

5.

Remove cable from temperature sensor.

6.

Remove upper inner hex bolts of rear toothed belt cover.

7.

Turn rear toothed belt cover to one side.

8.

Remove thermostat housing.

9.

Remove sealing ring from cylinder head.

Clean

Sealing surfaces in cylinder head and thermostat housing.

Installation

1.

Install sealing ring in recess of cylinder head.

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-33

2.

Install cable to temperature sensor.

3.

Install upper bolts of rear toothed belt rear cover.

4.

Install camshaft timing gear then check timing according
to the corresponding operation.

5.

Install camshaft housing cover.

6.

Install toothed belt and front cover.

7.

Fill up and bleed cooling system according to the
corresponding operation.

Tighten (Torque)

Thermostat housing to cylinder head - 15 N

⋅m/1.5 kgf⋅m.

Seal Ring - Front Camshaft Housing, Replace

Removal

Mark running direction of toothed belt.

Remove toothed belt-see operation “Toothed Belt, Replace”.

Camshaft housing cover, camshaft pulley-counterhold on hex

of camshaft.

Removal

Screw self-tapping screw into seal ring.

Edge out seal ring.

Installation

Lightly coat sealing lip of seal ring with protective grease.

Install seal ring with 5-8840-0451-0 into camshaft housing-use

screw and washer of camshaft pulley.