Disassembly; Inspection And Repair - Isuzu 1999 RODEO Workshop Manual

6A–58 ENGINE MECHANICAL (X22SE 2.2L)

Disassembly

1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove oil pan assembly.
4. Remove oil pan support.
5. Remove oil strainer.
6. Remove oil pump assembly.
7. Remove balance unit assembly.
8. Remove piston and connecting rod assembly.
9. Remove flywheel.
10. Remove rear oil seal retainer assembly.
11. Remove main bearing cap.
12. Remove crankshaft.
13. Remove cylinder block.

Inspection and Repair

1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the cylinder
block. Be very careful not to allow any material to
accidentally drop into the cylinder block. Be very
careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal retainer,
and crankcase assembly installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary, use a
flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must either
be repaired or replaced.
Flatness
1. Using a straight edge and feeler gauge, check that the
upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.40 mm (0.0156 in)
Maximum repairable limit: 0.40 mm (0.0156 in)
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
If the measurement exceeds the specified limit, the
cylinder block must be replaced.
Diameter
Grade 1 : 85.975 mm–85.985 mm
(3.3530 in–3.3534 in)
Grade 2 : 85.985 mm–86.025 mm
(3.3534 in–3.3550 in)
Oversize : 0.5 mm (0.0195 in)
NOTE: For information on piston diameter, please refer
to the section "Inspection of the Piston and Connecting
Rod Assembly" in this manual.
012RW013