Isuzu — Service Procedure

A Isuzu service procedure — check it applies to your exact model before use.

Procedure

1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical sys-
tem, always remove the minus side cable from the
battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.
4. Do not perform painting work or leave the engine
running for long periods of time in an enclosed or
badly ventilated indoor workshop.
5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may
cause damage to the parts or injury to the person
using the tool.
6. All regular tools, gauges and special tools should
be regularly inspected, and prepared before start-
ing work. Do not use bent spanners, hammers with
damaged edges, chipped chisels, or any other
faulty or damaged tools.
WSHK0190
General Information 0A-3
7. Always pay close attention to safety and handling
requirements when using grinders, cranes, weld-
ers, and other such equipment.
Moreover, always wear the correct protective gar-
ments and use the necessary safety tools for the
job in hand.
8. Always check that there are no fuel leaks when
performing maintenance work on the fuel system.
(It may cause a fire.)
9. Pay close attention to the risk of ignition if you are
handling parts that carry a high voltage.
Furthermore, any oil or grease spilt onto rubber
parts must be wiped off immediately, as it will
cause deterioration of the rubber.
Replacement parts and part numbers
1. Always replace packing, oil seals, O-rings, caulk-
ing lock nuts, folding lock plates, split pins and
other such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to revi-
sions. Therefore, parts should always be checked
against a parts catalogue before use.
WSHK0191
WSHK0192
0A-4 General Information
Liquid gasket
1. Each time you disassemble parts that use liquid
gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to com-
pletely remove oil, water, and dirt etc. from the var-
ious surfaces by a cloth. Using the specified type
of liquid gasket, apply new liquid gasket to each of
the surfaces before reassembling the parts.
2. In order to make it easier to clean liquid gasket sur-
faces, apply gasket remover liquid (Pando- 391D
made by ThreeBond Co., Ltd.) and leave the part
to stand for approximately 10 minutes, after which
the old liquid gasket residue will be easier to
remove.
However, this should not be used on resin compo-
nents or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when reinstalling
the liquid gasket parts to each other. If there are
gaps between the two parts, re-apply the liquid
gasket. Some parts, especially the oil pan, use the
same size studs as a guide to eliminate the need
for knock pin positioning etc.
5. Re-install these parts within 5 minutes of applying
the liquid gasket.
If more than 5 minutes passes, remove the previ-
ous liquid gasket and re-apply it.
6. Please wait for at least 30 minutes since the last
part is installed before starting the engine.
Liquid gasket
• Always use the liquid gasket products listed above, or a liquid gasket identical to the ones listed above.
• Use the correct quantity of liquid gasket. Always follow the handling instructions for each product.
Applied area
Use conditions
Liquid gasket
name
Parts
Matching parts
Seal object
Application
groove
1
Rocker bracket
Cylinder head
Engine oil (10W
— 30)
Equipped
TB 1207B
2
Air inlet pipe
Cylinder head cover
Air
Equipped
TB 1207C
3
Timing case
Cylinder block
Engine oil (10W
— 30)
Equipped
TB 1207B
4
Housing cover; injection pump
Cylinder block
Engine oil (10W
— 30)
None
TB 1207C
5
Solenoid; fuel cut
Cylinder block
Engine oil (10W
— 30)
Equipped
TB 1207C
6
Retainer; oil seal
Cylinder block
Engine oil (10W
— 30)
Equipped
TB 1207B
7
Housing ASM; PCV
Cylinder head cover
Blow-by gas
None
TB 1207C
8
Indicator; air cleaner
Air cleaner
Air
None
(Seal tape)
General Information 0A-5
Application procedure
1. Wipe the contact surfaces clean of all water, oil or
grease. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.
Note:
If there are special regulations concerning the applica-
tion procedure in the repair document, please follow
those regulations.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
threads clean of water, grease, and oil. The con-
tact surfaces should be dry.
2. Apply Loctite to the top 1/3 of the screw.
3. Tighten the bolt to the specified torque.
Important:
After tightening the bolt, do not apply excessive
torque or try to rotate the bolt until at least one
hour has passed, and the Loctite has hardened.
Procedure for using the plastigauge
Example: Procedure for measuring the clearance
between the connecting rod bearing and crank pin.
• Clean the connecting rod and bearing, and install
the bearing to the rod.
• Cut the plastigauge to the same width as the crank
pin, and while avoiding the oil hole of the crank pin
lay the gauge parallel to the pin.
• Line up the marks on the connecting rod and cap,
and install the crank pin. Apply molybdenum disul-
fide to the thread section and seating surface of
the tightening bolt, and rotate both cap and bolt to
the correct torque.
Important:
Do not move the connecting rod while using the
plastigauge.
• Gently remove the cap and connecting rod, and
measure the crushed width of the plastigauge
(clearance between rod and pin) using the scale
printed on the bag.
Type
Measurable range mm {in}
PG-1 (Green)
0.025 — 0.076 {0.001 — 0.003}
PR-1 (Red)
0.051 — 0.152 {0.002 — 0.006}
PB-1 (Blue)
0.102 — 0.229 {0.004 — 0.009}
0A-6 General Information
Exam

Source: manual:SM-JCB-Isuzu-Engine-AU-4LE2-BV-4LE2-2.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.