Isuzu Trooper (1998-2002 year). Manual - part 568

6A – 80 ENGINE MECHANICAL

2. Piston and Connecting Rod Assembly

1) Apply engine oil to the cylinder bores, the

connecting rod bearings and the crankshaft pins
and each piston ring and piston.

2) Align the front mark (2) of piston and front mark

(3) of connecting rod then assemble them.

3) The N mark of the piston ring is faced toward the

top, check to see that the piston ring end gap is
correctly positioned.

Legend

(1) 1st piston ring end gap
(2) 2nd piston ring end gap
(3) Oil ring end gap

4) Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Piston Ring Compressor: 5-8840-9018-0

5) Match the numbered caps with the numbers on

the connecting rods. Align the punched marks
on the connecting rods and caps.

6) Apply engine oil to the threads and seating faces

of the nuts.

7) Tighten the cap nuts in 2 steps, using angular

tightening method as shown in the following
specifications.

1st step: 29 N·m (3.0 kg·m/22 lb ft)
2nd step: 45°– 60°

After tightening the cap nuts, check to see that
the crankshaft rotates smoothly

3. Piston Cooling Oil Pipe

If the piston cooling oil pipe is forcibly assembled,
the end of the oil jet may bend. It could make it
impossible to supply oil to the piston cooling holes,
which will sometimes cause piston seizure.
Sufficient care should be taken to pipe assembly
work.
1) Tighten the bolt and oil jet plug to the specified

torque.

Torque:

M6: 8 N·m (0.8 kg·m/69 lb in)
M8: 20 N·m (2.0 kg·m/14 lb ft)

Oiling Jet Plug: 30 N·m (3.1 kg·m/22 lb ft)

4. Crank case

1) Refer to “Crank case” in this manual.

5. Apply liquid gasket (TB-1207C or equivalent) to

retainer then install it to rear end of cylinder block
within 5 minutes.

6. Crankshaft Rear Oil Seal

1) Tighten the adapter to the crankshaft rear and

section with 2 bolts.

2) Insert the oil seal into the peripheral section of

the adapter.

NOTE: Apply oil to the oil seal lip.

3) Insert the sleeve into the adapter and tighten it

with a bolt (M12 x 1.75L = 70) until the adapter
hits the sleeve.

4) Remove the adapter and the sleeve.
5) Check the dimension of the oil seal setting from

rear end of crankshaft.

Standard Dimension = 12.5 ± 0.3 mm

Oil Seal Installer: 5-8840-2359-0

2

3

1

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3

1

2

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ENGINE MECHANICAL 6A – 81

7. Cylinder Block Rear Plate (A/T)

Align the rear plate with the cylinder block dowel
pins.
Tighten the rear plate to the specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)

8. Flywheel housing (M/T)

Align the flywheel housing with the cylinder block
dowel pins.
Tighten the bolt to the specified torque.

Torque: 97 N·m (9.9 kg·m/72 lb ft)

9. Flywheel

1) Thoroughly clean and remove the oil from the

threads of crankshaft and flywheel fixing
surface.

2) Mount the flywheel on the crankshaft and then

install the washer.

3) Align the timing mark, cut out on the flywheel is

at lowest position for M/T

model and

identification hole on the boss is highest position
for A/T model when cylinder No. 1 is at the TDC.

For M/T Model

For A/T model

4) Tighten the flywheel bolts in 2 steps using

angular tightening method.

Torque:  1st step  59 N·m (6.0 kg·m/43 lb ft)
Torque:  2nd step  60° – 90°
Torque:  3rd step  60° – 90°

10. Timing Gear Case

1) Cut away the gasket protruding between the

cylinder block and the crank case fitting surfaces
(as shown in the illustration).

12.5 + 0.3

–

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Timing mark

278

74

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Timing mark

74

φ

304

015RW120

7

5

1

3

8

6

2

4

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6A – 82 ENGINE MECHANICAL

2) Apply liquid gasket (TB1207B or equivalent)

between the cylinder block and the crankcase
fitting surfaces.

3) Install the timing gear case to the cylinder body.
4) Tighten the timing gear case bolt together with

the timing gear case gasket to the specified
torque.

Torque: 20 N·m (2.0 kg·m/14 lb·ft)
11. Crankshaft Gear

1) Set key to crankshaft key groove.
2) The timing mark on the crankshaft gear must be

facing outward.

3) Use the crankshaft gear installer to install the

crankshaft gear.
Crankshaft installer: 9-8522-0021-0

Legend

(1) Crankshaft Gear Installer
(2) Crankshaft Gear

12. Installation of the Timing Gear

1) Align teeth on the scissors gear and lock them

before install timing gear.

2) Align timing marks on each timing gear and

assemble them.

3) Refer to timing gear detail in this manual.

13. Timing Gear Case Cover

1) Remove lock bolt from idle gear A and remove

lock pin from idle gear C.

2) Install oil pump gear oil seal before assembling

timing gear case cover.

3) Clean fitting surface and apply liquid gasket

(TB1207C or equivalent) to fitting surface.

4) Tighten bolts to specified torque.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

1

2

2

012RW066

2

2~2.5mm

2~2.5mm

Apply liquid gasket around inside 
of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

012RW024

012RW064

14. Crankshaft Front Oil Seal

1) Set oil seal with special tool.
2) Install front oil seal to timing gear case cover.
Crankshaft Front Oil Seal Installer: 5-8840-2061-0

NOTE: Apply oil to the oil seal lip.

3) Remove special tool and check oil seal position

from front surface of timing gear case.

Oil Seal Position: 0.5 – 2.5 mm (0.0197 – 0.0984 in)

15. Cylinder Head

1) Refer to “Cylinder head” in this manual.

ENGINE MECHANICAL 6A – 83

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