Isuzu Thermo King 2.2L Diesel Engines (di 2.2/se 2.2) OEM Service & Repair Manual

This manual is published for informational purposes only and the information so provided should not be considered as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request. Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manufacturer’s plants as, in the manufacturer’s judgment, to effect its stability.” No warranties, express or implied, including warranties of fitness for a particular purpose or merchantabil- ity, or warranties arising from course of dealing or usage of trade, are made regarding the information, rec- ommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure.

This manual covers the overhaul, repair and maintenance procedures for Thermo King di and se 2.2 diesel engines. Design changes and improvements have been made to the di and se 2.2 engines over the years in a continuing effort by Thermo King to provide the latest in diesel engine technol- ogy. Before beginning any service to your engine, please review the engine chart on page 108 to determine which version di or se 2.2 engine you have. Doing so will help assist the mechanic with determining special service procedures and interchangeability of components between the various engines. Although the di 2.2 and se 2.2 engines are different ver- sions of the same engine, the following components are not interchangeable: Injection pump, gear case cover, gear case backing plate, oil base, transfer pump, flywheel housing, intake and exhaust manifolds, oil filter and housing, crankcase breather, water pump, thermostat housing and timing gears. Refer to the Parts Interchange Section located in the rear of the manual. APA06 Thermo King di 2.2 Diesel Engine All Thermo King 2.2 diesel engines are four cylinder, four stroke, water cooled engines that use a direct injection fuel system. The engines are configured so that all maintenance can be performed from one side of the engine. This heavy duty engine is designed with five main bearings on the crankshaft. Its rugged construction, when combined with a routine preventive maintenance program, will provide many hours of satisfactory service. Eventually, even the best designed engines require an overhaul. This manual provides the proper procedures to restore the engine to a rebuilt condition. A properly rebuilt engine will provide thousands of further hours of satisfactory service. The specifications section lists the sizes and tolerances used in the original assembly of the engine. All tables for oversize and wear limits for particular components are found in the sections dealing with these specific components.

Thermo King se 2.2 Diesel Engine

Table of Contents di 2.2 & se 2.2 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque Values for di 2.2 & se 2.2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Crankshaft Wear Ring (radial seal only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Transfer Pump Cam Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Cylinder Head Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lifters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Wrist Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Engine Breathing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assembly Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Cam Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Crankshaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Rear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Rear Crankshaft Seals and Seal Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Idler Gear Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Pistons and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Bellhousing / Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Table of Contents—continued Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Transfer Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Installation and Timing of Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Gear Reduction Starter (Hitachi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Starter Disassembly and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Engine Run In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Bleeding Air from the Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Dynamometer Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Testing Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Parts Interchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 se 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Gear Mounting Flange Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Oil Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Oil Filter and Oil Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Intake and Exhaust Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1 di 2.2 & se 2.2 Diesel Engine Specifications The following specifications are given for a standard engine. Except where noted, the specifications for both engines are the same. For oversize tables or allowable wear limits, refer to the appropriate section in the text. General Type Four Stroke, Four Cycle, Water Cooled Number of Cylinders 4 Cylinder Arrangement In-line Vertical, Number 1 at pulley end Bore 3.465 in. (88 mm nominal) Stroke 3.622 in. (92 mm nominal) Displacement 136.6 cu in. (2238.5 cm3) Horsepower 34.8 @ 2200 rpm Fuel Injection Timing Refer to engine chart on page 108 to determine correct timing. 0.02 in. (0.5 mm) @ 14 BTDC (timed on No. 1 cylinder) 0.02 in. (0.5 mm) @ 6 BTDC (timed on No. 1 cylinder) Valve lash: Intake (cold) 0.016 in. (0.40 mm) Exhaust (cold) 0.016 in. (0.40 mm) Firing order 1-3-4-2 Compression ratio 20:1 Compression pressure More than 427 psi (2942 kPa) @ 250 rpm High speed (transport units)* 2200 rpm (Varies with unit. Check specific unit manual) Low speed (transport units)* 1300 to 1350 rpm (Varies with unit. Check specific unit manual) Oil pressure (hot) More than 43 psi (294 kPa) @ 1400 rpm More than 64 psi (441 kPa) @ 2200 rpm Nozzle injection pressure 2633 to 2704 psi (18142 to 18632 kPa) Oil base capacity 16 qts (15.2 liters) Engine serial number Stamped on cylinder block just above oil filter Engine rotation Clockwise (viewed from pulley end) Valve Spring and Guide Valve Spring: Free Length 1.81 in. (46 mm) Inclination 0.118 in. (3.0 mm) Set length 1.52 in. (38.6 mm) Tension at set length 43.4 lb (19.7 kg) Valve Guide Inside Diameter: Intake 0.3150 to 0.3156 in. (8.001 to 8.017 mm) Exhaust 0.3150 to 0.3156 in. (8.001 to 8.017 mm) Valve Stem Outside Diameter: Intake 0.3128 to 0.3141 in. (7.946 to 7.978 mm) Exhaust 0.3119 to 0.3131 in. (7.921 to 7.953 mm) * Consult the applicable service manual for correct speed settings.

di 2.2 & se 2.2 Diesel Engine Specifications (Rev. 05/01) 2 Valve Spring and Guide (continued) Valve Stem Clearance: Intake 0.0015 to 0.0028 in. (0.039 to 0.071 mm) 0.0025 to 0.0034 in. (0.064 to 0.086 mm) Exhaust Valve Guide set depth (from valve spring seat): Intake 0.475 in. (12.07 mm) 0.475 in. (12.07 mm) Exhaust Valve Depth Intake 0.011 negative to 0.007 in. positive (0.275 to 0.175 mm) Exhaust 0.011 negative to 0.007 in. positive (0.275 to 0.175 mm) Valve Seat angle 45 degrees Valve Face angle 45 degrees Valve Seat contact width: Intake 0.054 to 0.069 in. (1.38 to 1.76 mm) Exhaust 0.048 to 0.063 in. (1.22 to 1.60 mm) Valve margin 0.051 in. (1.3 mm) Valve Train Lifter diameter 0.5108 in. (12.97 mm) Lifter clearance to block 0.0004 to 0.0016 in. (0.01 to 0.4 mm) Push rod length 8.150 in. (207 mm) Rocker arm bore 0.7484 to 0.7500 in. (19.01 to 19.05 mm) 0.7476 to 0.7480 in. (18.99 to 19.00 mm) Rocker arm shaft diameter Rocker arm to shaft clearance 0.0004 to 0.0024 in. (0.01 to 0.06 mm) Camshaft Lobe height: Intake 1.5913 in. (40.42 mm) Exhaust 1.5984 in. (40.60 mm) Cam lift: Intake 0.245 in. (6.22 mm) Exhaust 0.252 in. (6.40 mm) Cam bearing bore 1.9682 to 1.9710 in.(49.99 to 50.06 mm) Journal diameters 1.9670 to 1.9675 in. (49.96 to 49.97 mm) Clearance to bearing 0.0010 to 0.0034 in. (0.025 to 0.085 mm) End play (set by thrust plate) 0.002 to 0.004 in. (0.05 to 0.11 mm) Piston, Piston Rings Piston, type: Cam ground-full float pin Diameter Grade A 3.4633 to 3.4640 in. (87.967 to 87.986 mm)

di 2.2 & se 2.2 Diesel Engine Specifications (Rev. 05/01) 3 Piston, Piston Rings (continued) Grade B 3.4637 to 3.4644 in. (87.977 to 87.996 mm) Grade C 3.4641 to 3.4648 in. (87.987 to 88.006 mm) Grade D 3.4644 to 3.4652 in. (87.997 to 88.016 mm) Clearance to cylinder wall 0.0020 to 0.0025 in. (0.051 to 0.064 mm) Wrist pin bore 1.2206 to 1.2209 in. (31.002 to 31.010 mm) Projection above block 0.022 to 0.040 in. (0.572 to 1.018 mm) Piston rings Ring to groove clearance (top side): No. 1 compression 0.0017 to 0.0037 in. (0.043 to 0.094 mm) 0.0017 to 0.0037 in. (0.043 to 0.094 mm) 0.0017 to 0.0037 in. (0.043 to 0.094 mm) No. 2 compression No. 3 compression No. 4 oil control 0.0019 to 0.0037 in. (0.048 to 0.094 mm) Ring end gap: No.1 0.004 to 0.014 in. (0.10 to 0.35 mm) No. 2 0.008 to 0.014 in. (0.20 to 0.35 mm) No. 3 0.006 to 0.012 in. (0.15 to 0.30 mm) No. 4 0.004 to 0.014 in. (0.10 to 0.35 mm) Piston Wrist Pin: Length 2.795 in. (71 mm) Outside diameter 1.2205 in. (31 mm) Inside diameter 0.709 in. (18 mm) Clearance to rod bushing 0.0004 to 0.0008 in. (0.01 to 0.02 mm) Connecting Rods Large-end bore 2.205 in. (56 mm) Allowable twist per 4 in. (100 mm) Less than 0.002 in. (0.05 mm) Allowable parallelism per 4 in.(100mm)Less than 0.002 in. (0.05 mm) Side clearance to journal 0.007 to 0.011 in. (0.175 to 0.290 mm) Width 1.30 in. (33 mm) Crankshaft Main bearing I.D. 2.3608 in. to 2.3622 (59.96 to 60.00 mm) Main bearing journal diameter 2.3589 to 2.3595 in. (59.917 to 59.932 mm) Main bearing clearance 0.0013 to 0.0033 in. (0.035 to 0.083 mm) Rod bearing I.D. 2.0859 to 2.0849 (52.98 to 52.96 mm) Rod bearing journal diameter 2.0832 to 2.0838 in. (52.915 to 52.930 mm) Rod bearing clearance 0.0011 to 0.0027 in. (0.029 to 0.069 mm) Rear seal surface diameter 3.937 in. (100 mm) Crankshaft end play 0.002 to 0.008 in. (0.05 to 0.20 mm)

di 2.2 & se 2.2 Diesel Engine Specifications (Rev. 05/01) 4 Cylinder Block Main bearing bore 2.5197 in. (64 mm) Lifter bore 0.5110 to 0.5125 in. (12.98 to 13.018 mm) Cylinder wall finish 16 micro-inch Timing Gears (varies with engine model) Gear width: Crank gear 1.024 in. (26 mm) Idler gear, camshaft 1.535 in. (39 mm) Idler gear, injection pump 0.669 in. (17 mm) Injection pump gear 0.669 in. (17 mm) Camshaft gear 1.024 in. (26 mm) Idler gear, crankshaft: Bushing inside diameter 1.7717 to 1.7728 in. (45.000 to 45.030 mm) Support diameter 1.7695 to 1.7707 in. (44.945 to 44.975 mm) Bushing to support clearance 0.0010 to 0.0033 in. (0.025 to 0.085 mm) Timing gear backlash: Crank gear to camshaft idler gear 0.0023 to 0.0035 in. (0.058 to 0.090 mm) Camshaft idler gear to injection pump idler gear 0.0004 to 0.0075 in. (0.010 to 0.189 mm) Injection pump idler gear to injection pump gear 0.0012 to 0.0041 in. (0.030 to 0.105 mm) 0.0024 to 0.0035 in. (0.061 to 0.089 mm) Camshaft idler gear to camshaft gear Cylinder Head Height 3.62 in. (92 mm) Valve seat material Martensitic heat resisting steel Valve seat insert bore (intake) 1.5748 to 1.5760 in. (40 to 40.03 mm) Valve seat insert bore (exhaust) 1.3386 to 1.3398 in. (34 to 34.03 mm) Valve seat outside diameter: Intake 1.5791 to 1.5799 in. (40.11 to 40.13 mm) Exhaust 1.3429 to 1.3437 in. (34.11 to 34.13 mm) Bore for valve guides 0.5512 to 0.5520 in. (14.000 to 14.021 mm) Valve guide O.D. 0.5522 to 0.5528 in. (14.026 to 14.040 mm) Lubrication System Oil pump Type Gear pump Delivery volume 4.15 gal/min. (15.7 liters) @ 1,000 pump rpm Relief Valve set at 40 to 65 psi (275 to 448 kPa) Oil filter bypass valve set at 11 to 17 psi (78 to 118 kPa)

Isuzu Thermo King 2.2L Diesel Engines (di 2.2/se 2.2) OEM Service & Repair Manual

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