Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 572

6A – 126  ENGINE MECHANICAL

14.  Piston Cooling Oil Pipe

1)  Install the piston cooling oil pipe to the cylinder body.

2)  Tighten the oil pipe bolts and relief valve to the

specified torque.

Oil Pipe Bolt Torque

kg·m (lb.ft/N·m)

c

 M8 

×

 1.25

1.9 

±

 0.5 (13.7 

±

 3.6/18.6 

±

 4.9)

d

 M6 

×

 1.00

0.8 

±

 0.2 (5.8 

±

 1.5/7.8 

±

 2.0)

Relief valve Torque

kg·m (lb.ft/N·m)

e

 M16 

×

 1.5

3.0 

±

 0.5 (21.7 

±

 3.6/29.4 

±

 4.9)

Note:

Check that there is no interference between the piston
and the oiling jet pipe 

f

f

f

f

 by slowly rotating the

crankshaft.

15.  Oil Pump with Oil Pipe

Install the oil pump with the oil pipe and tighten the bolts to
the specified torque.

Oil Pump Bolt Torque

kg·m (lb.ft/N·m)

                                                                                                                   

1.9 

±

 0.5 (13.7 

±

 3.6/18.6 

±

 4.9)

                                                                                                                   

Note:

Take care not to damage the O-rings when tightening
the oil pipe bolts.

16. Oil Pan

1)  Apply the recommended liquid gasket (three bond

TB1207 & TB1207C) or its equivalent to arch gasket
fitting surface as shown in the illustration.

2)  Install the crank case front gasket 1 to the timing gear

case arches.

The gasket projection 2 must be facing forward.

3)  Install the rear arch gasket 2 to the No. 5 bearing cap.

Use your fingers to push the arch gasket into the
bearing cap groove.

Take care not to scratch the arch gasket outer
surface.

Also apply the recommended liquid gasket (TB1207B
& TB1207C) or its equivalent to arch gasket fitting
area as indicated in the illustration.

ENGINE MECHANICAL   6A – 127

4)  Apply the recommended liquid gasket or its equivalent

to groove of the crank case fitting surface as shown in
the illustration.

Note:

Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.

5)  Install the crank case to the cylinder body.

6)  Tighten the crank case bolts to the specified torque a

little at a time in the sequence shown in the illustration.

Crank Case Bolt Torque

kg·m (lb.ft/N·m)

                                                                                                                   

1.9 

±

 0.5 (13.7 

±

 3.6/18.6 

±

 4.9)

                                                                                                                   

17.  Cylinder Body Rear Plate

1)  Align the rear plate with the cylinder body knock pins.

2)  Tighten the rear plate to the specified torque.

Rear Plate Torque

kg·m (lb.ft/N·m)

                                                                                                                   

8.4 

±

 0.8 (60.8 

±

 5.8/83.3 

±

 7.8)

                                                                                                                   

18. Flywheel

1)  Block the crankshaft with a piece of hard wood to

prevent the flywheel from turning.

2)  Apply a coat of engine oil to the threads of the flywheel

bolts.

3)  Align the flywheel with the crankshaft dowel pin.

4)  Tighten the flywheel bolts to the specified torque in the

numerical order shown in the illustration.

Flywheel Bolt Torque

kg·m (lb.ft/N·m)

                                                                                                                   

12.0 

±

 0.5 (86.8 

±

 3.6/117.6 

±

 4.9)

                                                                                                                   

6A – 128  ENGINE MECHANICAL

19.  Crankshaft Timing Pulley

1)  Install the timing pulley to the crankshaft.

2)  Use the crankshaft timing pulley installer to install the

timing pulley.

The timing pulley flange must be facing the cylinder
body.

20.  Crankshaft Timing Pulley Center

1)  Install the crankshaft timing pulley center.

2)  Use the fixing wrench to prevent the crankshaft from

turning.

Fixing Wrench: 5-8840-0161-0

3) Tighten the crankshaft pulley center bolt to the

specified torque.

Crankshaft Pulley Center Bolt Torque

kg·m (lb.ft/N·m)

4JA1T

19.0 

±

 2 (137.4 

±

 14.5/186.20 

±

 19.60)

4JG2T

28.0 

±

 4.5 (202.5 

±

 32.5/274.4 

±

 44.1)

21. Injection Pump

1)  Install the injection pump 

c

 to the timing pulley

housing 

d

.

2)  Temporarily tighten the three injection pump nuts 

e

.

The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.

3)  Install the injection pump rear bracket 

f

 and the rear

bracket bolts 

g

 to the cylinder body.

4)  Install the rear bracket bolts 

h

 to the injection pump

bracket.

Do not tighten the bolts.

The rear bracket bolts 

g

 and 

h

 will be finally tighten

tened to the specified torque after the injection pump
nuts.

5) Tighten the injection pump nuts to the specified

torque.

Injection Pump Nut and Bracket Bolt
Torque

kg·m (lb.ft/N·m)

g

, 

h

1.9 

±

 0.5 (13.7 

±

 3.6/18.6 

±

 4.9)

ENGINE MECHANICAL   6A – 129

22.  Injection Pump Timing Pulley

1)  Align the timing pulley with the pump shaft key.

2)  Install the stopper bolt 

c

 to the timing pulley.

This will prevent the timing pulley from turning.

3) Tighten the timing pulley nut to the specified torque.

Injection Pump Timing Pulley Nut Torque kg·m (lb.ft/N·m)

                                                                                                                   

6.5 

±

 0.5 (47.0 

±

 3.6/63.7 

±

 4.9)

                                                                                                                   

23. Tension Idler

1)  Install the tensioner idler to the timing pulley housing.

2)  Tighten the tensioner idler to the specified torque.

Tensioner Idler Bolt Torque

kg·m (lb.ft/N·m)

                                                                                                                   

7.7 

±

 1.0 (55.7 

±

 3.6/75.5 

±

 9.8)

                                                                                                                   

24. Timing Belt

25. Timing Belt Tensioner

26. Timing Belt Tension Adjusting Lever

1) Check that the stopper bolts are properly installed to

the camshaft timing pulley 

c

 and the injection pump

timing pulley 

d

.

2) Check that the timing pulley housing mark 

e

 and the

crankshaft timing pulley mark 

f

 are aligned.

3)  Install the timing belt to the crankshaft timing pulley

g

, the camshaft timing pulley 

h

, the tensioner idler

i

, and the injection timing pulley 

j

.

Follow the numerical order.

4)  Install the timing belt tensioner 

k

 to the timing pulley

housing.

5)  Temporarily tighten the tnesioner bolt.

The tensioner should move freely.

Note:

The timing belt is easily damaged. Be careful.