Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1690

6A-58 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

4.

Heat a new con-rod to 280

°C in the oil bath.

5.

Install the con-rod to the piston and insert the piston pin.

Important!

Since the con-rods have no weight balancing studs, re-working

is not possible.

Exchange con-rods in sets only.

Installation position, beads on con-rod point to the flattening on

the piston pin eye.

Firmly seated piston pin cannot be pushed in. Carry out

installation quickly.

Piston Rings

Removal

1.

Remove piston with con-rod according to the
corresponding operation.

2.

Remove piston rings using commercially available ring
installer or piston ring clamp pliers.

Clean

Piston ring grooves - ground piece of old piston ring

Inspection

Piston ring gap

For piston ring sizes, permissible piston ring gaps - see

"Technical Data"

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-59

Installation

1.

Install oil scraper ring.

2.

Offset ring gaps of steel band rings each 25 to 50 mm/1
to 2in. to the left or right of the intermediate ring gap.

3.

Install piston rings.

4.

Offset ring gaps by approx. 180

°.

5.

Install second piston ring with identification mark "TOP"
facing upwards.

6.

Install piston with con-rod according to the corresponding
operation.

6A-60 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

OPERATIONS ON REMOVED ENGINE

Crankshaft

Removal

1.

Mount the engine on an engine overhaul stand with
appropriate adapters.

2.

Remove the aggregates, flywheel/drive disc, oil pan, and
oil pump according to the corresponding operation.

3.

Mark the con-rod bearing cover.

4.

Remove the crankshaft bearing cover.

5.

Remove the crankshaft from cylinder block.

Inspection

Remove and install all parts if necessary.

Crankshaft pulse pickup sensor rotor inspection and repair.
Inspect the crankshaft pulse pickup sensor rotor for excessive
wear and damage.
Replace the crankshaft pulse pickup rotor if the inspection
results exceed wear and damage limits.

Installation

1.

Install the crankshaft pulse pickup sensor.
Torque: 13N

!!!!m (1.3 kgf!!!!m)

2.

Install new bearing shells into the cylinder block and
bearing cover.

3.

Coat the bearing shafts with engine oil.
For oversizes-see “Technical Data”

4.

Install a new crankshaft into the cylinder block.

Note

The sealing of the crankshaft can be corrected with light

blows with a rubber hammer on the crank arm (arrowed).

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-61

5.

Apply a bead of sealant (TB-1207C or equivalent) in the
grooves of both bearing shells.

Important!

After installation of bearing cover, press in sealing compound

again from above, until compound emerges at the joints.

Torque - Angle Method

Bearing cover to cylinder block - 50 N

⋅m (5.1 kgf⋅m) +40° to 50°

Con-rod bearing cover to con-rod - 35 N

⋅m (3.5 kgf⋅m) +45° to

60

°.

Use new bolts.

6.

Install oil pump, oil pan, rear crankshaft sealing,
flywheel/drive plate, and aggregates according to the
corresponding operations.

Inspection

Bearing play - bearing cover removed

Measure

With "Plastigage" (ductile plastic threads)

Cut threads to length of bearing width and lay axiaity between

crankshaft journal and bearing shell (arrowed).

Install bearing cover with correct torque.

Important!

Grease crankshaft journal and lubricate bearing shell slightly so

that the thread does not tear when the bearing cover is moved.

Crankshaft

Inspection

End play when bearing shells are installed.

Front end contact surfaces of flywheel/flexible plate.

Permissible end play - see "Technical Data "