How do you overhaul Isuzu diesel engine?

Answer 1

Remove head, oil pan,pistons w/connecting rods, and liners. Replace pistons, rings, liners, rod bearings, and if possible role new main bearings in too. Check head for cracks, burnt valves, worn/damaged valve guides and seats and repair/replace accordingly. Always replace injector cups if applicable. reinstall pan, head. If it has a mechanical injection pump or 2004 and older it WILL need to be removed and calibrated. It's an expensive thing to do but is completely necessary if you want Isuzu to cover the new parts you just installed. Especially if a piston is melted. The melting is caused by over injecting of fuel by the injection pump. Their is no way to know it's happening until it's too late. So every rebuild that has mechanical injection pump will need to be calibrated so for one no melting occurs and so Isuzu will warranty the new pistons and other parts installed.