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Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 575

6A – 138 ENGINE MECHANICAL

1. Timing

Gear

Case

1) Tighten the timing gear case with timing gear case

gasket to the specified torque.

Timing Gear Case Bolt Torque

kg·m (lb.ft/N·m)

1.9

± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

2. Camshaft

Thrust

Plate

Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.
Thrust Plate Bolt Torque

kg·m (lb.ft/N·m)

1.8

± 0.5 (13.0 ± 3.6/17.6 ± 4.9)

3. Camshaft Timing Gear

1) Install the camshaft timing gear to the camshaft.

The timing gear mark (“Y – Y” or “：”) must be facing
outward.

2) Tighten the timing gear to the specified torque.
Timing Gear Bolt Torque

kg·m (lb.ft/N·m)

11.0

± 1 (79.6 ± 7.2/107.8 ± 9.8)

4. Crankshaft Timing Gear

Use the crankshaft timing gear installer

to install the

crankshaft timing gear

The crankshaft timing gear setting mark (“X – X” or “・”)
must be facing outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0

5. Idler Gear Shaft
6. Idler Gear “A”

1) Apply engine oil to the idler gear and the idler gear

shaft.
The idler gear shaft oil hole

must be facing up.

2) Position the idler gear setting marks “X” or “・”, “Y” or

“：” and “Z” or “∴” so that they are facing the front of
the engine.

ENGINE MECHANICAL 6A – 139

3) Align the idler gear “X” or “：” setting mark with the

crankshaft timing gear

“X – X” or “：” setting mark.

4) Align the idler gear “Y” or “・” setting mark with the

camshaft timing gear

“Y – Y” or “・” setting mark.

5) Install the thrust collar and bolts to the cylinder body

through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.

6) Tighten the idler gear bolt to the specified torque.
Idler Gear “A” Bolt Torque

kg·m (lb.ft/N·m)

3.0

± 0.5 (21.7 ± 3.6/30 ± 5.0)

7. 7a. Idler Gear “B” and Shaft

1) Apply engine oil to the idler gear and the idler gear

shaft.

2) Align the idler gear “B”

“Z” or “∴” setting mark with

the idler gear “A”

“Z – Z” or “∴” setting mark.

3) Tighten the idler gear bolt to the specified torque.
Idler Gear “B” Bolt Torque

kg·m (lb.ft/N·m)

7.7

± 1.0 (55.7 ± 7.2/74 ± 9.8)

7a. If the idle gear “B” is disassemble, reassemble in the

following procedure.

Idle Gear B (scissor gear) Reassembly Steps (4JA1TC,
4JH1TC only)

1) Drive pins into the main gear, the front gear, and the

rear gear.

2) Apply pressure to the main gear bearing from the front

side of the main gear (the side with the groove).

020L200019

020L200007

6A – 140 ENGINE MECHANICAL

3) Place the special tool in a vise so that the main gear is

pushed up toward the rear side.

Scissor gear setting tool

Base 5-8673-9149-0

4) Set the spring as shown in the illumination.

5) Position the rear gear so that it pin is aligned with the

receiving end of the spring.

6) Install the snap ring to the main gear groove.

7) Set the rear gear setting hole to the pin of the special

tool.

8) Place the special tool in a vise so that the main gear is

pushed up toward the front side.

9) Repeat Steps 3, 4, and 5.

020L200008

020L200009

020L200010

020L200011

020L200013

ENGINE MECHANICAL 6A – 141

10) Use the special tool to mesh the teeth of the front

gear, the main gear, and the rear gear.

Scissor gear setting tool

Lever 5-8673-9150-0

11) Insert a lock bolt (M6×1 L=30) into the scissor gear

fixing hole to prevent the scissor gear from turning.

8. Timing Gear Oil Pipe (Except 4JA1TC, 4JH1TC)

1) Install the oil pipe to the timing gear case and idler

gear “A”.

2) Tighten the oil pipe eye bolt

and bolt

to the

specified torque.

Eye Joint and Bolt Torque

kg·m (lb.ft/N·m)

1.25

± 0.25 (9.0 ± 1.8/12.3 ± 2.5)

9. Injection

Pump

1) Install

the

O-ring

to the injection pump flange

2) Install the injection pump to the timing gear case.

Align the idler gear “B”

“V – V” or “‥” mark with the

injection pump timing gear

“V” or “‥” mark.

020L200014

020L200012

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