Content .. 571 572 573 574 ..

Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 573

6A – 130 ENGINE MECHANICAL

6) Set the tensioner adjusting lever

to the timing

pulley housing.

7) Remove the stopper bolts from the camshaft timing

pulley

and the injection pump timing pulley

8) Attach the spring balancer

9) Adjust timing belt tension by pulling straight down on

the spring balancer with the specified force.

Tension Adjusting Lever Force

kg (lb/N)

10 - 12 (22.1 – 26.5/98.1 – 117.7)

Note:

Timing belt tension must be adjusted.

Failure to adjust the timing belt tension will result in
timing belt damage.

10) Tighten the tension bolt.

11) Rotate the crankshaft 45 degrees counterclockwise.

Note:

Never rotate crankshaft clockwise when adjusting the
timing belt.

12) Readjust the timing belt tension.

Refer to Step 9

This will remove any remaining timing belt slack.

13) Tighten the tensioner bolt to the specified torque.

Tensioner Bolt Torque

kg·m (lb.ft/N·m)

7.7

1.0 (55.7

3.6/75.5

9.8)

14)Tighten the tension adjusting lever nut

and bolt

Note:

If on-vehicle timing belt replacement is performed, the
crankshaft must not be allowed to turn.

If the crankshaft is allowed to turn, piston and valve
damage will result.

ENGINE MECHANICAL 6A – 131

27. Camshaft Timing Pulley Flange

Tighten the timing pulley flange bolts to the specified
torque.

Timing Puley Flange Bolt Torque

kg·m (lb.ft/N·m)

1.9

0.5 (13.7

3.6/18.6

4.9)

28. Water Pump

1) Apply the recommended liquid gasket or its equivalent

to the water pump at the position shown in the
illustration.

Do not apply an excessive amount of liquid gasket.

2) Tighten the water pump bolts to the specified torque.

Water Pump Bolt Torque

kg·m (lb.ft/N·m)

2.0

0.5 (14.5

3.6/19.6

4.9)

29. Timing Pulley Housing Lower Cover

30. Timing Pulley Housing Upper Cover

1) Apply the recommended liquid gasket or its equivalent

to the timing pulley lower cover.

2) Install the lower cover

to the timing pulley housing

Use the lower cover guide bolts

to prevent the

liquid gasket from running.

3) Install the upper cover

to the lower cover and pulley

housing.

4) Tighten the timing cover bolts to the specified torque a

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

Timing Pulley Cover Bolt Torque

kg·m (lb.ft/N·m)

0.8

0.2 (5.8

1.4/7.8

2.0)

5) Remove the lower cover guide pin.

6A – 132 ENGINE MECHANICAL

32. Cylinder Head Gasket

The cylinder head gasket “TOP” mark must be facing up.

Note:

Before the gasket installation, measure the piston
head projection and select the appropriate head
gasket.

Refer to “INSPECTION AND REPAIR”, “Cylinder Head
Gasket Selection”.

33. Cylinder Head

1) Align the cylinder body dowels and the cylinder head

dowel holes.

Carefully place the cylinder head on the cylinder head
gasket.

2) Apply a coat of engine oil to the cylinder head bolt

threads and setting faces.

3) Tighten the cylinder head bolts in two steps.

Follow the numerical sequence shown in the
illustration.

Cylinder Head Bolt Torque

kg·m (lb.ft/N·m)

1st Step

2nd Step

3rd Step

5.0

0.5

(36.2

3.6/49.00

4.90)

~ 75

Cylinder Head Bolt Torque

kg·m (lb.ft/N·m)

1st Step

2nd Step

New
bolt

5.0

0.5

(36.2

3.6/

83.3

4.9)

8.7

0.5

(62.9

3.6/

85.26

4.90)

4JB1
For
CHINA
only

Reuse
bolt

8.5

0.5

(61.4

3.6/

83.3

4.9)

10.5

0.5

(75.9

3.6/

102.90

4.90)

015RY00031

ENGINE MECHANICAL 6A – 133

35. Rocker Arm Shaft and Rocker Arm

Tighten the rocker arm shaft bracket bolts in the numerical
order shown in the illustration.

Rocker Arm Shaft Bracket Bolt Torque

kg·m (lb.ft/N·m)

5.5

0.5 (39.8

3.6/53.9

4.9)

36. Thermostat Housing

1) Install the thermostat housing.

2) Tighten the thermostat housing bolts to the specified

torque.

Thermostat Housing Bolt Torque

kg·m (lb.ft/N·m)

1.9

0.5 (13.7

3.6/18.6

4.9)

38. Glow Plug and Glow Plug Connector

1) Install the glow plugs to the cylinder head.

2) Tighten the glow plugs to the specified torque.

Glow Plug Torque

kg·m (lb.ft/N·m)

2.25

0.25 (16.3

1.8/22.1

2.5)

3) Install the glow plug connector.

39. Injection Nozzle Holder

1) Install the injection nozzle gasket

and the O-ring

to the injection nozzle holder

Be sure that the O-ring fits snugly in the injection
nozzle groove.

2) Install the nozzle holder toghther with the nozzle holder

bracket

to the cylinder head.

Nozzle Holder Bracket Bolt Torque

kg·m (lb.ft/N·m)

3.8

0.6 (27.5

4.3/37.2

5.9)

3) Tighten the holder nut with washer

to the specified

torque.

Injection Nozzle Holder Nut Torque

kg·m (lb.ft/N·m)

3.8

0.6 (26.0

4.3/37.2

5.9)

Content .. 571 572 573 574 ..