Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 569

6A – 114  ENGINE MECHANICAL

Important Operations

3.  Valve Stem Oil Seal

1)  Apply a coat of engine oil to the oil seal inner face.

2)  Use an oil seal installer to install the oil seal to the

valve guide.

Oil Seal Installer: 5-8840-2033-0

4.  Intake and Exhaust Valve

1)  Apply a coat of engine oil to each valve stem before

installation.

2)  Install the intake and exhaust valves.

3)  Turn the cylinder head up to install the valve springs.

Take care not to allow the installed valves to fall free.

5. Valve 

Spring

Install the valve spring with their fine pitched end (painted)
facing down.

7. Split 

Collar

1)  Use the spring compressor to compress the valve

spring into position.

Spring Compressor: 9-8523-1423-0 (J-29760)

2)  Install the split collars to the valve stem.

3)  Set the split collars by tapping around the head of the

collar with a rubber hammer.

8.  Intake Manifold Gasket

9. Intake 

Manifold

1)  Install the manifold gasket with the end having the

sharp corners facing the front of the engine.

2)  Install the intake manifold to the cylinder head.

3)  Tighten the manifold bolts to the specified torque.

Manifold Bolt Torque

kg·m (lb.ft/N·m)

                                                                                                                   

1.9 

±

 0.5 (13.7 

±

 3.6/18.6 

±

 4.9)

                                                                                                                   

ENGINE MECHANICAL   6A – 115

 PISTON AND CONNECTING ROD

Reassembly Steps

t

1.

Piston

t

5.

Piston pin snap ring

t

2.

Piston pin snap ring

t

6.

Piston ring

t

3.

Connecting rod

t

7.

Connecting rod bearing

t

4.

Piston pin

015L200003

For 4JA1/4JA1T/4JA1TC

/4JH1TC only

6A – 116  ENGINE MECHANICAL

Important Operations

1. Piston

2. Piston Pin Snap Ring

3. Connecting Rod

1)  Clamp the connecting rod in a vise.

Take care not to damage the connecting rod.

2) Use a pair of pliers to install the piston pin snap ring to

the piston.

Install the piston to the connecting rod so that the piston
head front mark 

c

 and the connecting rod “ISUZU”

casting mark 

d

 are facing in the same direction.

4. Piston 

Pin

1)  Apply a coat of engine oil to the piston pin and the

piston pin hole.

2)  Use your fingers to force the piston pin into the piston

until it makes contact with the snap ring.

5.  Piston Pin Snap Ring

3)  Use your fingers to force the piston pin snap ring into

the piston snap ring groove.

4)  Check that the connecting rod moves smoothly on the

piston pin.

015R100022

015R100018

ENGINE MECHANICAL   6A – 117

6. Piston 

Ring

1)  Use a piston ring replacer to install the three piston

rings.

Piston Ring Replacer

Install the piston rings in the order shown in the
illustration.

c

Oil ring

d

 

2nd compression ring

e

 

1st compression ring

Note:

Install the compression rings with the stamped side
facing up.

Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.

2)  Apply engine oil to the piston ring surfaces.

3)  Check that the piston rings rotate smoothly in the

piston ring grooves.

7.  Connecting Rod Bearing

Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.