ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Injection Pump

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Exploded view of the diesel injection pump

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover.
  4.  
  5. Remove the fuel lines.
  6.  
  7. Using a prybar, remove the tension spring from the timing belt tensioner.
  8.  

When removing the tension spring, avoid using excessive force, or the spring may become distorted.

  1. Remove the tensioner pulley bolt and the pulley.
  2.  
  3. Remove the timing belt and discard it.
  4.  
  5. Using a 6mm x 1.25 pitch bolt, install the threaded portion into the threaded hole in the timing pulley housing through the hole in the pulley. This prevents the pulley from turning.
  6.  
  7. Remove the injection pump pulley-to-shaft bolts.
  8.  
  9. Using a wheel puller, connect it to the injection pump pulley and press it from the shaft.
  10.  
  11. Remove the injection pump bracket-to-timing pulley housing bolts, the rear injection pump-to-bracket bolts and the injection pump.
  12.  

To install:
  1. Install the injection pump. Tighten the injection pump-to-timing pulley housing bolts and leave the rear pump-to-bracket bolts semi-tight.
  2.  
  3. Install the injection pump pulley by aligning it with the key groove and tighten the bolt to 42-52 ft. lbs. (57-70 Nm).
  4.  
  5. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.
  6.  
  7. Align the timing marks on the injection pump pulley with the camshaft pulley; the marks must be facing each other.
  8.  
  9. Using a new timing belt, install it in the following sequence: crankshaft pulley, camshaft pulley and the injection pump pulley; the slack must be between the injection pump and camshaft pulleys.
  10.  
  11. Install the tension center and the tension pulley so the end of the tension center is fitted against both pins on the timing pulley housing.
  12.  
  13. Hand-tighten the nut so the tension pulley can be rotated freely.
  14.  
  15. Install the tension spring and tighten the pulley nut to 22-36 ft. lbs. (29-48 Nm).
  16.  
  17. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.
  18.  
  19. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-130 Nm).
  20.  
  21. Install the injection pump pulley flange; the hole in the outer circumference of the flange should be aligned with the triangular timing mark on the injection pump pulley.
  22.  
  23. Rotate the crankshaft 2 full turns clockwise to bring the No. 1 piston to TDC of the compression stroke. Make sure the triangular timing mark on the timing pulley is aligned with the hole in the flange, then measure the timing belt tension; it should be 33-55 lbs. (147-246 N).
  24.  
  25. Install the timing belt cover.
  26.  
  27. Connect the negative battery cable.
  28.  

INJECTION TIMING



See Figures 2, 3 and 4



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Fig. Fig. 2: Diesel injection pump timing marks



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Fig. Fig. 3: Timing indicator



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Fig. Fig. 4: Turning the injection pump in its mount will advance or retard the timing

  1. Check to see if the notched lines on the injection pump and mounting plate are aligned.
  2.  
  3. Bring the No. 1 piston to Top Dead Center (TDC) on the compression stroke by turning the crankshaft. The correct notch must be used for alignment, as the damper pulley is provided with a total of seven notches.
  4.  
  5. Remove the front upper timing belt cover, then check the timing belt for proper tension and alignment of the timing marks.
  6.  
  7. Remove the cam cover and rear plug, then check that the fixing plate (J-29761 or equivalent) fits smoothly into the slit at the rear end of the camshaft. Remove the fixing plate.
  8.  
  9. Disconnect the injection pipe from the injection pump and remove the distributor head screw and gasket, then install a static timing gauge. Set the lift about 0.039 in. (1mm) from the plunger.
  10.  
  11. Bring the No. 1 piston to a point 45-60° before TDC by turning the crankshaft, then calibrate the dial indicator to zero.
  12.  

The damper is provided with notched lines. The four lines at one side are for static timing and should be used for service purposes. The three lines are for dynamic timing and used only at the factory.

  1. Turn the crankshaft until the line 12° on the damper is brought into alignment with the pointer, then take a reading of the dial indicator. It should be 0.019 in. (0.5mm).
  2.  
  3. If the reading on the dial indicator deviates from the specified range, hold the crankshaft to the injection pump setting listed in the Diesel Tune-up Specifications chart in General Information & Maintenance . Loosen the two nuts on the injection pump flange.
  4.  
  5. Move the pump to a point where the dial indicator gives a reading of 0.019 in. (0.5mm). Tighten the flange nuts.
  6.  

 
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