Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1691

6A-62 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

Inspection

Out-of-round (run-out)-middle bearing shell removed when

mounting on front and rear bearing.

Permissible out-of-round - see "Technical Data"

Bearing Free Play Measurement

Two methods for measuring bearing free play are described -

1. Plastigage method and 2. micrometer and gauge method.

The two procedures are suitable for measuring both con-rod

and main bearing free play.

For both methods ensure con-rod and main bearing caps are

identified (1) prior to removal as they are machine matched.

1.Plastigage Method
Removal

1.

Remove bearing cap and shell.

2.

Lightly coat journals and bearings with engine oil to
prevent Plastigage from tearing when cap is removed.

Installation

1.

Lay a length of Plastigage across width of crank pin and
fit bearing cap and shell using old bolts at this stage.

Important!

Do not allow crankshaft to rotate.

Torque - Angle Method

Main bearing cap bolt - 60 N

⋅m (6.1 kgf⋅m) +40° + to 50°.

Con-rod bearing cap bolts - 35 N

⋅m (3.6 kgf⋅m) +45°.

Removal

1.

Remove bearing cap and shell.

Measure

Width of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or

main journal bearing clearance exceeds 0.04mm/0.02in. -

check crankshaft journal diameters - see corresponding

operation.

Replace bearing if crankshaft is within specification - see

"Technical Data"

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-63

Clean

Plastigage from journals.

Lightly coat journals and bearings with engine oil.

Installation

Install bearing cap and shell using new bolts.

Torque - Angle Method

Main bearing cap bolt - 60 N

⋅m (6.1 kgf⋅m) +40° to 50°.

Con-rod bearing cap bolts - 35 N

⋅m (3.9 kgf⋅m) +45°.

2.Micrometer and gauge method.

Crankshaft removed.

Installation

1.

Install caps and bearing shells to con-rods and cylinder
block.

Measure

Con-rod and main bearing diameters at three points I, II, III

(arrowed).

Divide the sum of the three measurements by three to obtain a

mean diameter.

The top illustration shows con-rod measuring points.

The second illustration shows main bearing measuring points.

Measure

Crankshaft main and con-rod bearing journals at points I and II.

Divide the sum of both measurements to obtain a mean

diameter.

Crankshaft must be replaced if mean diameter of main or con-

rod journals is below specified limit - see "Technical Data".

If crankshaft is serviceable subtract crankshaft mean journal

diameters from corresponding shell bearing mean diameters to

determine bearing clearance.

Permissible main bearing clearance - 0.015 to 0.04mm/0.0006

to 0.002in.

Permissible con-rod bearing clearance - 0.006 to

0.031mm/0.002 to 0.001in.

6A-64 ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE)

Bypass Valve

Removal

1.

Remove oil filter.

2.

Remove bypass valve by cutting thread in locking disc
with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.

Installation

1.

Install bypass valve using drift (diameter approx.
15mm/0.6in.).

Oil Filter

Removal

1.

Remove oil filter using commercially available tool.

Installation

1.

Install oil filter by hand and oil seal ring.

2.

Fill up engine oil while preventing overflow.

Oil Pump

Removal

1.

Remove rear toothed belt cover, and oil pan according to
the corresponding operations.

2.

Remove oil filter, wiring plug from oil pressure switch, oil
pump from cylinder block, and oil pressure switch from oil
pump.

Clean

Sealing surfaces

Installation

1.

Install oil pressure switch to oil pump, oil pump to cylinder
block, oil pan, wiring plug, oil filter and toothed belt cover.

Tighten (Torque)

Oil pressure switch to oil pump - 30 N

⋅m (3.2 kgf⋅m)

Oil pump to cylinder block - 6 N

⋅m (0.6 kgf⋅m)

Oil intake pipe to oil pump - 8 N

⋅m (0.8 kgf⋅m)

Intake pipe bracket to cylinder block - 8 N

⋅m (0.8 kgf⋅m)

*Insert bolts with Locktite (Refer to General Description

Recommended Liguid Gasket)

ENGINE MECHANICAL (C24SE, C22NE, 22LE, 20LE) 6A-65

Oil Pump Safety Valve

Removal

1.

Remove closure plug.

2.

Remove seal ring.

3.

Remove spring.

4.

Remove piston.

Installation

1.

Install piston (observe installation position).

2.

Install spring.

3.

Install seal ring.

4.

Install closure plug.

Tighten (Torque)

Closure plug - 30 N

⋅m (3.0 kgf⋅m)

Oil Pump (Overhaul)

Removal

1.

Remove oil pump according to the corresponding
operation.

2.

Remove oil cover and pressure control valve.

Inspect

Clearance between gear pair and housing upper edge - see

“Technical Data”.

Check housing, cover and pressure control valve.

Installation

1.

Install pump cover with Sealing Compound 15 03 166 (90
094 714).

2.

Install oil pump safety valve according to the
corresponding operation.

3.

Install oil pump according to the corresponding operation.