Engine Mechanical: Overhaul Isuzu Axiom I

Disassembly

Note. During disassembly, be sure that the valve train components are kept together and identified so that they can be reinstalled in their original locations. Before removing the cylinder head from the engine and before disassembling the valve mechanism, perform a compression test and note the results.

Scheme 108

1. Remove camshaft drive gear pulley fixing bolt (3), then pulley (4).
2. Remove camshaft bearing cap fixing bolt (5), camshaft bearing cap (6), then camshaft exhaust (7), and intake side (8).
3. Remove tappet with shim (11).
4. Use the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to remove the split collar (12), valve spring with upper seat (13) and valve (14).
5. Remove spark plug (1).

Clean

Cylinder head

Carefully remove all varnish, soot and carbon from the bare metal. Do not use surface conditioning disc on any gasket sealing surface.

Scheme 109

1. Inspect cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, determine the cause. Insufficient torque on head bolts Improper installation Loose or warped cylinder head Missing dowel pins Warped case surface
2. Inspect cylinder head for cracks, especially between valve seats and in the exhaust ports.
3. Inspect cylinder head deck for corrosion, sand particles in head and porosity. CAUTION: Do not attempt to weld the cylinder head. Replace it. Do not reuse cylinder head bolts.
4. Inspect cylinder head deck, common chamber and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are "out of flat" with "round" by more than specification, the surface should be ground to within specifications. Replace the head if it requires machining beyond the repairable limit. Head surface and manifold surface Standard: 0.05 mm (0.002 in) or less Warpage limit: 0.2 mm (0.0079 in) Maximum Repairable limit: 0.2 mm (0.0079 in) Head height Standard height: 133.2 mm (5.2441 in) Warpage limit: 0.2 mm (0.0079 in) Maximum Repairable limit: 133.0 mm (5.2362 in)
5. Water jacket sealing plugs seating surfaces.

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

1. Install Spark plug and tighten all the spark plugs to specified torque. Torque: 18 N.m (13 lb ft)
2. Tighten sub gear setting bolt. Use J-42686 gear spring lever to turn sub gear to right direction until the M5 bolt aligns with the hole between camshaft driven gear and sub gear. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving.
3. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque: 10 N.m (87 lb in)
4. Install camshaft assembly and camshaft bearing cap, tighten twenty bolts on one side bank to the specified torque. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).
5. Tighten twenty bolts in numerical order on each bank as shown in the illustration. Torque: 10 N.m (87 lb in)
6. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque: 98 N.m (72 lb ft)

Scheme 115

Scheme 116

1. Remove camshaft bearing cap fixing bolts (1).
2. Remove camshaft assembly (intake).
3. Remove camshaft assembly (Exhaust side).
4. Remove shim (4) and tappet (5).
5. Use the J-8062 valve spring compressor and J-42898 valve spring compressor adapter to remove split collar.
6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the J-42899 valve guide replacer.

1. Remove cylinder head assembly (1). Refer to «CYLINDER HEAD»(ref-194298-S37972772472005092700000) .
2. Remove crankcase with oil pan (2). Refer to «OIL PAN AND CRANKCASE»(ref-194304-S08079399982005092700000) . CAUTION: Take care not to damage or deform the sealing flange surface of crankcase.
3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8). Refer to «PISTON, PISTON RING AND CONNECTING ROD»(ref-194298-S09702860352005092700000) .
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).

1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.
5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.