Isuzu Truper - Isuzu Trooper
1. The maintenance instruction
2. Maintenance service
3. Engines
   3.1. Specifications of the engine and adjusting works
   3.2. An electric equipment and major repairs of engines
      3.2.1. An electric equipment of engines
      3.2.2. Major repairs of engines
         3.2.2.1. Technical characteristics
         3.2.2.2. Instructions on service and engine repair
         3.2.2.3. Dismantle and installation of the power unit
         3.2.2.4. A cover of a head of cylinders
         3.2.2.5. Коромысла and platens коромысел
         3.2.2.6. The thermostat
         3.2.2.7. A soaking up collector
         3.2.2.8. A final collector
         3.2.2.9. Турбокомпрессор
         3.2.2.10. The conditioner
         3.2.2.11. A radiator
         3.2.2.12. The fan of system of cooling with a drive from the electric motor
         3.2.2.13. The pump of a cooling liquid
         3.2.2.14. A head of cylinders
            3.2.2.14.1. Removal and installation
            3.2.2.14.2. Clearing and condition check
         3.2.2.15. Valves and springs
         3.2.2.16. Pushers
         3.2.2.17. The oil pallet
         3.2.2.18. The oil pump
         3.2.2.19. An epiploon of a forward cover of a gear belt
         3.2.2.20. A chain of a drive of a camshaft and a drive asterisk
         3.2.2.21. A forward cover of a gear belt
         3.2.2.22. An epiploon of a cranked shaft
         3.2.2.23. A gear belt and натяжитель
         3.2.2.24. A gear belt and the tension mechanism
         3.2.2.25. A drive газораспределительного the mechanism petrol engines
         3.2.2.26. A drive газораспределительного the mechanism diesel engines
         3.2.2.27. A camshaft
         3.2.2.28. Camshaft bearings
         3.2.2.29. Pistons and rods
         3.2.2.30. Shatunnye bearings
         3.2.2.31. Assemblage of shatunno-piston group and installation on the engine
         3.2.2.32. Заглушки and a heater картера the engine
         3.2.2.33. A back epiploon of a cranked shaft
         3.2.2.34. A cranked shaft and radical bearings
         3.2.2.35. A flywheel and a gear wreath
   3.3. The diesel engine of 2,8 litres
4. System of decrease in toxicity
5. Fuel system
6. Transmission and a running gear
7. A suspension bracket and a steering
8. Brake system
9. A body
10. A body electric equipment
11. Diagnostics of malfunctions
12. Electroschemes





Isuzu Trooper>> Engines>> Electric equipment and major repairs of engines>> Major repairs of engines>> Head of cylinders

3.2.2.14. A head of cylinders

3.2.2.14.1. Removal and installation ENGINES 4ZD1

Removal

PERFORMANCE ORDER
1. Disconnect the battery from weight. Merge cooling liquid.
2. Expose the piston of 1st cylinder in ВМТ a compression step, having convinced of combination of adjusting labels. Uncover the ignition distributor, put position labels бегунка concerning the case of the distributor and position of the case of the distributor concerning a head of cylinders. Remove a collar of the distributor and the distributor.
3. Disconnect from a radiator inlet and final hoses.
4. Remove belts of a drive of the generator and the conditioner. Remove the fan.
5. Turn away the central bolt of a pulley of a cranked shaft and remove a pulley in gathering with a nave.
6. Remove a belt of a drive of the air pump and take the pump aside. Remove the conditioner compressor (if it is provided) and take aside. Remove a compressor arm.
7. Remove a pulley of the pump of a cooling liquid. Remove the top part of a forward cover, remove the pump.
8. Remove the bottom part of a forward cover.
9. Remove a spring. Ослабьте the top bolt of a roller натяжителя and to the full displace a roller towards the location of the pump of a cooling liquid.
10. Remove a gear belt.
11. Uncover heads of cylinders.
12. Remove platens in gathering with коромыслами and support for what gradually weaken an inhaling of nuts of fastening of support, since the most remote nuts from the central part.
13. Lift the car, disconnect an exhaust pipe from a final collector. On cars with a turbo-supercharging disconnect an exhaust pipe from a final branch pipe турбокомпрессора and remove a drive cable.
14. Lower the car, disconnect all tubes, hoses, sockets of conducting and a wire of spark plugs.
The prevention

Before a detachment put on all hoses identification labels.


15. Disconnect draught of a drive throttle заслонки, on engines with a turbo-supercharging remove all conducting from atomizers and disconnect a fuel highway from a distributive branch pipe.
16. Turn away bolts of a head of cylinders. Turn on gradually, since extreme angular bolts. If the bolt does not give in отворачиванию moisten with its getting liquid.
17. Together with the assistant remove a head of cylinders in gathering with soaking up and final collectors.

Installation

Sequence of an inhaling

And – an order of an inhaling of covers of platens коромысел: nuts 1–8 tighten with the moment 22 Н.м.; nuts 9 and 10 – with the moment 7 Н.м.

– sequence of an inhaling of a head of cylinders on engines 4ZD1


PERFORMANCE ORDER
1. Clear socket planes on the block of cylinders and on a head. Check up a plane condition, presence on it of deep scratches, or hollows.
2. Clear carvings of bolts of a head of cylinders and in reciprocal apertures in the block, otherwise the inhaling moment will not correspond to the real.
3. Impose a new lining of a head on old, check up conformity of linings.
4. Establish a lining and a head of cylinders on the block, turn and tighten bolts of a head of cylinders. An inhaling carry out in 2 stages: at 1st stage tighten bolts with the moment 57 Н.м., and at 2nd stage – the moment 96 Н.м.
5. Attach draught of a drive throttle заслонки, on engines with a turbo-supercharging attach all conducting to atomizers and attach a fuel highway to a distributive branch pipe.
6. Attach all tubes, hoses, sockets and high-voltage wires to spark plugs.
7. Lift the car, attach an exhaust pipe to a final collector. On cars with a turbo-supercharging attach an exhaust pipe to a final branch pipe турбокомпрессора and attach a drive cable.
8. Establish platens in gathering with коромыслами and support, tighten nuts in the specified sequence (fig. Sequence of an inhaling see).
9. Dress a gear belt.
10. Dress a spring натяжителя a belt. Tighten the top bolt of a roller натяжителя.
11. Establish the bottom part of a forward cover.
12. Establish a pulley of the pump of a cooling liquid, the top part of a forward cover, establish the pump.
13. Establish the air pump and a drive belt. Establish an arm of the compressor of the conditioner and the compressor (if it is provided).
14. Establish a pulley of a cranked shaft, wrap the central bolt.
15. Establish the generator, dress a belt of a drive of the conditioner. Establish the fan.
16. Attach to a radiator inlet and final hoses.
17. Establish the ignition distributor, fix a distributor collar.
18. Connect the battery to weight. Fill in cooling liquid, be convinced of absence of a leak.

THE ENGINE 4ZE1

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, observing rules. Disconnect the battery from weight. Merge cooling liquid.
2. Remove belts of a drive from the pump of the hydraulic booster, the air pump, the fan of system of cooling and the conditioner compressor (if it is provided).
3. Expose the piston of 1st cylinder in ВМТ a compression step.
4. Uncover the distributor of ignition with high-voltage wires and the ignition distributor.
5. Turn away bolts of fastening of an exhaust pipe to a final collector.
6. Put identification labels and disconnect all electric sockets and vacuum hoses which can prevent dismantling.
7. Disconnect hoses of system of cooling, remove a radiator and the fan.
8. Turn away a bolt of a pulley of a cranked shaft and remove a pulley.
9. Remove the top and bottom covers of a gear belt, a spring and a gear belt.
10. Turn away a bolt of a conducted gear wheel of a camshaft, remove a gear wheel and the plug.
11. Remove directing a gear belt and a forward plate of a head of cylinders.
12. Uncover heads of cylinders and a lining.
13. Turn away bolts of a head of cylinders, remove a head and a lining.

Installation

Sequence of an inhaling

And – an order of an inhaling of covers of platens коромысел on engines 4ZЕ1

– sequence of an inhaling of a head of cylinders on engines 4ZD1


PERFORMANCE ORDER
1. Establish a new lining, a head of cylinders and tighten bolts in the set sequence (fig. Sequence of an inhaling see). An inhaling carry out in 2 stages: at 1st stage tighten bolts with the moment 76 Н.м., and at 2nd stage – the moment 88–108 Н.м.
2. Establish a conducted gear wheel of a camshaft.
3. Establish a cover of a head of cylinders, preliminary having replaced a lining.
4. Combine labels on a camshaft and on a forward plate. Be convinced that the flute turned upwards under шпонку on a cranked shaft is directed on the index on the block of cylinders.
5. Establish a gear belt in a following order: a pulley of a cranked shaft, a pulley of the oil pump, a camshaft, a roller натяжителя.
6. Establish covers of a gear belt, preliminary having replaced a lining.
7. Establish a pulley of a cranked shaft.
8. Establish hoses of system of cooling, a radiator and the fan.
9. Attach all electric sockets and vacuum hoses.
10. Wrap bolts of fastening of an exhaust pipe to a final collector.
11. Establish the ignition distributor, a cover of the distributor and high-voltage wires.
12. Establish belts of a drive of the pump of the hydraulic booster, the air pump, the fan of system of cooling and the conditioner compressor (if it is provided).
13. Connect the battery to weight. Fill in cooling liquid.
14. Start the engine, be convinced of absence of a leak.

ENGINES V6

Order of an inhaling of bolts of a head of cylinders on engines V6

The left head of cylinders

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, observing rules. Disconnect the battery from weight. Merge cooling liquid.
2. Remove soaking up collector.
3. Lift the car and establish on supports.
4. Turn away bolts of fastening of an exhaust pipe to a final collector, remove an exhaust pipe and turn away bolts of fastening of a final collector to a head of cylinders.
5. Remove a branch pipe маслоуказателя.
6. Lower the car.
7. Turn away a nut коромысел, raise коромысло and get bars of pushers. Store details so that at assemblage to establish on former places.
8. Turn away bolts of a head of cylinders as it should be the return specified in illustrations.
9. Remove a head of cylinders. It is forbidden to hook for head removal by its sharp tool.
10. Clear a head.

Installation

PERFORMANCE ORDER
1. Dress on directing pins a new lining so that the inscription "This side up" has been turned upwards. Cautiously establish a head of cylinders.
2. Establish bars of pushers, be convinced that bars have rested against pushers. Tighten nuts коромысел with the moment 20–27 Н.м.
3. Establish soaking up collector.
4. Establish маслоуказатель.
5. Wrap bolts of fastening of a final collector to a head of cylinders and bolts of fastening of an exhaust pipe to a final collector.
6. Fill in cooling liquid. Start the engine, be convinced of absence of a leak.

The right head of cylinders

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, observing rules. Disconnect the battery from weight. Merge cooling liquid.
2. Remove soaking up collector.
3. Remove a cruise-control arm, the gate and a hose of the distributor of air.
4. Lift the car and establish on supports.
5. Turn away bolts of fastening of an exhaust pipe to a final collector and nuts of fastening of a final collector to a head of cylinders.
6. Disconnect an exhaust pipe, remove a collector and a thermal guard (if it is provided).
7. Lower the car.
8. Put identification labels and disconnect conducting and vacuum hoses which can prevent removal of the right head.
9. Turn away a nut коромысел, raise коромысло and get bars of pushers. Store bars of pushers so that at assemblage to establish on former places.
10. Turn away bolts of a head of cylinders as it should be the return specified in illustrations.
11. Remove a head of cylinders. It is forbidden to hook for head removal by its sharp tool.
12. Clear a head.

Installation

PERFORMANCE ORDER
1. Dress on directing pins a new lining so that the inscription "This side up" has been turned upwards. Cautiously establish a head of cylinders.
2. Establish bars of pushers, be convinced that bars have rested against pushers. Tighten nuts коромысел with the moment 20–27 Н.м.
3. Establish soaking up collector.
4. Establish a collector of an exhaust pipe, an exhaust pipe and a thermal guard (if it is provided).
5. Wrap bolts of fastening of a final collector to a head of cylinders and nuts of fastening of an exhaust pipe to a final collector.
6. Establish a cruise-control arm, the gate and a hose of the distributor of air.
7. Fill in cooling liquid. Start the engine, be convinced of absence of a leak.

DIESEL ENGINES С223 AND С223Т

Sequence of an inhaling

And – sequence of an inhaling коромысел on diesel engine С223 (the moment 20 Н.м.)

– sequence of an inhaling of a head of cylinders on diesel engine С223

In – position of a lining of a head of cylinders on diesel engine С223

1 – a label "Top"

Removal

PERFORMANCE ORDER
1. Depressurize fuel system, observing rules. Disconnect the battery from weight. Merge cooling liquid.
2. Remove the fan of system of cooling in gathering and a drive belt. Remove the generator and an arm.
3. Remove the top hose of a radiator and a hose () a heater.
4. Remove the air filter and an air line.
5. Put identification labels and disconnect vacuum hoses and conducting sockets.
6. Remove the fuel distributor, a collar and the holder of atomizers.
7. Remove spark plugs and the resistive gauge.
8. Uncover турбокомпрессора and турбокомпрессор.
9. Remove soaking up and final collectors.
10. Uncover heads of cylinders, a cover of pushers of valves and a tube of a supply of oil to коромыслам.
11. Turn away fastening bolts коромысел to a head of cylinders and remove коромысла.
12. Get bars of pushers and store them so that at assemblage to establish on former places.
13. Turn away bolts of a head of cylinders in an order, the return specified in fig. Sequence of an inhaling. Remove a head of cylinders. If the head does not give in to removal cautiously knock with a rubber hammer and get moving forward.
14. Compare old and new linings of a head of cylinders. Clear demountable surfaces of a head and the block of cylinders.

Installation

PERFORMANCE ORDER
1. Lay a new lining so that the inscription "Top" has been turned upwards.
2. Fill турбокомпрессор with fresh oil for the engine.
3. Establish a head of cylinders. Oil bolts of a head for the engine and turn. Tighten bolts in a following order, observing sequence of an inhaling.
On diesel engines with турбокомпрессором:
      – 1st stage – 45–54 Н.м.;
      – 2nd stage – to tighten on 120–150 .
On diesel engines without турбокомпрессора:
      – 1st stage – 54–63 Н.м.;
      – 2nd stage – 74–81 Н.м. (New bolts) or 61–69 Н.м. (Old bolts).
4. Establish bars of pushers, be convinced that bars have rested against cams.
5. Establish коромысла and tighten bolts with the moment 14–24 Н.м. Adjust a backlash in valves.
6. Other works on installation are carried out upside-down. Linings replace new.
7. Fill in cooling liquid. Connect the battery to weight. Start the engine, be convinced of absence of a leak.