Engine removal

[ken]

I am trying to get the engine out of my 94 bighorn but it seems to be Superglued to the gearbox. I think I have all the bolts out but can't get it to separate. Anybody got any advice? Thanks
Ken

[James W]

Hi Ken,

What engine and what gearbox? helps us to help you :-)

If it's a manual box have you got the three really hard bolts on top? one dead top center, two a little bit either side.... I can post pics if necessary..... but generally if they don't move, take a step back and try and think and/or find what is missed... there will be a reason

[ken]

Thanks James
It is a 4JG2 engine and an automatic gearbox
Ken

[isuzumudman]

Hi Ken,

I had a similar problem on a manual one and found I had missed a bolt over by the exhaust. Once I got that out it just slipped out.

Hoswever, reading the auto trans disassembly procedure, it seems you need to remove the flywheel under covers and undo 6 torque converter bolts. Gain access to them by rotating crank shaft. Then remove the transmission fixing bolts.

Hope this helps.
Dave

[ken]

Thanks Dave. I needed that info. I think it still comes apart but if you dont undo those bolts the torque convertor comes out with the flywheel.
Ken

[ken]

Hopefully I will have my engine out tomorrow. I am expecting broken rings. What options are there? Fit new rings throughout and perhaps a new piston. Or get all cylinders relined at $500 plus and new rings. Or is it possible to re-bore 20thou oversize and fit new pistons. This would get rid of the chrome but is the cast block suitable. Anybody else been along this road?
Ken

[jack4x4]

Hi ken
Dismantle, inspect and measure.......then decide.
What was the result of the compression test?
Your engine has only done 100,000Ks so wear should not be an issue.

If you need a free 4JG2 engine workshop manual, .....page2

www.isuzu.spottedhaggis.com/index.php?option=com_docman&task=cat_view&gid=13&Itemid=33

[geeves]

No rebore possible. Liners are chrome and the 500 is each but includes piston and rings but anouther option is std iron liners that are heaps cheaper. You use iron rings in chrome bores or chrome rings in iron bores If you use the same metal for each they will be stuffed before the run in period is over. Let us know what you find when you get the head off It might point to why it failed.

[ken]

I didn't get a compression test because the blow-by was so bad I thought it would be pretty obvious where the problem was.

I was labouring under an illusion about the bores. I thought they were chrome plated but it is apparent they are solid chrome liners.

As soon as the weather improves I will be into it as I don't have the hight in the garage to lift the engine out.
Thanks
Ken

[geeves]

How much more height do you need. You can get more height by letting down your tyres or even removing the front wheels although if you have to move the car after lifting the engine this option would make moving the car fairly hard.
sounds like it could be a while before any decent amount of good weather

[ken]

Hi guys
Not able to download that manual.
Having a bit of a job getting the engine out. Does the sump have to come off first?
Thanks
Ken

[jack4x4]

clubisuzu.proboards29.com/index.cgi?board=Engine&action=display&thread=1413
I haven't had cause to remove the 4JB1T/4JG2 but I can see the problem with the sump and front crossmember.
Sometimes it pays to remove the cylider head first and then you wouldn't have the firewall clearance problem.
Of coarse it's not out of the question to do a simple piston/ring/big end job with the engine in the vehicle.

[geeves]

pm me your postal address and I will send the manual on cd
alan

[ken]

Thanks Alan
Ken

[JustinW]

I got the 4JG2 out and back in the Wizard with the sump and head on. Obvious question - have you taken the alternator, power streering pump, A/C, turbo and fan off and the radiator out?

[ken]

The head is still on but all the rest are off. I see that the sump is in two parts. Haven't come across that before. It looks as though the bottom part can be taken off which would allow the oil pick-up pipe to be removed and hopefully the engine should then clear the axle, But I will wait until I get the disks from Alan before proceeding with that.
Thanks
Ken

[isuzumudman]

I just completed the shoe horn exercise with 4jg2 engine and manual trans mated into my swb Bighorn. It only just fitted after removing the steering gear, dropping the diff and dropping the body by removing the wheels. What a performance. I may do them separately next time but it's still easier to mate engine & trans out of the vehicle.
Dave

[ken]

I finally have the engine out. I took the bottom sump off it it was not too bad to get out. All I have to do now is fix the engine!!!
Ken

[ken]

I should have said - After taking the bottom sump off remove the oil pickup pipe else it will get wiped off when you slide the engine over the front axle
Ken

[ken]

Looking for cylinder head torque settings 4JG2 engine. I think the manual I have has a misprint. Not able to find it on club site.
Thanks
Ken.