Isuzu Cylinder Head Disassembly

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Example: 2002 Isuzu Trooper LS V6 3.5 Liter DOHC-4 Wheel Drive-Automatic Transmission

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 mechanism, perform a compression test and note the results

1. Remove camshaft drive gear pulley fixing bolt (3) then pulley (4)
2. Remove camshaft bracket fixing bolt (5), camshaft bracket (6), the camshaft exhaust (7), and intake side (8).
3. Remove tappet with shim (11)
4. Use the 5-8840-2446-0 valve spring compressor and 5-8840-2547-0 valve spring compressor adapter to remove the split collar (12), valve spring with upper seat (13) and valve (14)

Valve Spring Compressor's

Image left shows Spring Strength Tester

image left shows Valve Spring Remover

NOTE: Clean dirt and debris from spark plug recess areas before removal.

Clean Cylinder head
Carefully remove all varnish, soot and carbon from the bare metal.
Do not use a motorized wire brush on any gasket sealing surface.

Inspection and Repair
1. 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. Cylinder head for cracks, especially between valve seats and in the exhaust ports
3. Cylinder head deck for corrosion, sand particles in head and porosity

NOTE: DO NOT REUSE CYLINDER HEAD BOLTS

4. 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" 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 inch) or less
Warpage limit: 0.2 mm (0.0079 inch)
Maximum Repairable limit: 0.2 mm (0.0079 inch)
Warpage limit: 0.2 mm (0.0079 inch)
Maximum Repairable limit: 133.0 mm (5.2362 inch)