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

Camshaft

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Most engines covered by this guide utilize lifters between the camshaft and valve train. On all engines equipped with lifters, a complete new set of lifters must be installed whenever the camshaft is replaced. Excessive camshaft and lifter wear can occur if they are not replaced as a set.

REMOVAL & INSTALLATION



1.8L and 2.0L Engines

See Figures 1, 2 and 3



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Fig. Fig. 1: Camshaft timing marks-1.8L and 2.0L engines



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Fig. Fig. 2: Camshaft timing marks-1.8L and 2.0L engines



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Fig. Fig. 3: Rocker arm bolt torque sequence-4-cylinder gasoline engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rocker arm cover.
  4.  
  5. Rotate the engine until the No. 4 piston is at Top Dead Center (TDC) on the compression stroke. Remove the distributor cap and mark the rotor to housing position.
  6.  
  7. Release the tension on the automatic timing chain adjuster by performing the following procedures:
    1. Using a small prybar, depress the lock lever on the automatic adjuster rearward.
    2.  
    3. Push on the automatic adjuster shoe and lock it into the retracted position by releasing the lever.
    4.  

  8.  
  9. Remove the camshaft sprocket-to-camshaft bolt, the sprocket and suspend the assembly on the wire; allow the chain to remain on the sprocket.
  10.  
  11. Remove the rocker arm brackets-to-cylinder head bolts and the rocker arm bracket assembly from the cylinder head.
  12.  
  13. Remove the camshaft from the cylinder head.
  14.  

To install:
  1. Lubricate the camshaft with engine oil and install it onto the cylinder head.
  2.  
  3. Install the rocker arm assembly onto the cylinder head and torque the bolts to 16 ft. lbs. (21 Nm).
  4.  
  5. Align the camshaft sprocket hole with camshaft dowel pin and install the sprocket. Torque the camshaft sprocket-to-camshaft bolt to 50-65 ft. lbs. (68-88 Nm).
  6.  
  7. Set the automatic adjuster by turning the adjuster slide pin 90° counterclockwise with a small prybar.
  8.  
  9. Adjust the valve lash.
  10.  
  11. Install the rocker arm cover and make sure the alignment marks are aligned.
  12.  
  13. To complete the installation, reverse the removal procedures. Start the engine and check and/or adjust the timing.
  14.  

2.2L Gasoline Engine
  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system and the engine oil.
  4.  
  5. Remove the radiator.
  6.  
  7. Remove the rocker arm cover.
  8.  
  9. Remove the cylinder head.
  10.  
  11. Remove the anti-rotation bracket bolts and brackets, then remove the valve lifters.
  12.  
  13. Remove the oil pump drive retaining bolt, then remove the drive by lifting and twisting.
  14.  
  15. Remove the crankshaft pulley and hub.
  16.  
  17. Remove the serpentine drive belt idler pulley.
  18.  
  19. Remove the timing cover from the engine.
  20.  
  21. Remove the timing chain and camshaft sprocket.
  22.  
  23. Remove the camshaft thrust plate retaining bolts, then remove the plate from the block.
  24.  
  25. Pull the camshaft straight out of the engine, turning slightly as it is withdrawn and taking care not to damage the bearings.
  26.  
  27. If necessary, remove the camshaft bearings using J-33049 or an equivalent camshaft bearing remover/installer.
  28.  

To install:
  1. Inspect the camshaft, journals and lobes for wear and replace, if necessary.
  2.  
  3. If removed, use the camshaft bearing tool to install a new set of bearings.
  4.  
  5. Coat the camshaft lobes and journals with a high viscosity oil with zinc such as No. 12345501, or equivalent.
  6.  
  7. Carefully insert the camshaft in the engine, turning it slightly from side to side and it is inserted.
  8.  
  9. Install the thrust plate and tighten the retaining bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install the timing chain and camshaft sprocket.
  12.  
  13. Install the timing cover to the engine.
  14.  
  15. Install the serpentine drive belt idler pulley.
  16.  
  17. Install the crankshaft pulley and hub.
  18.  
  19. Install the oil pump drive by inserting while twisting, then install the retaining bolt and tighten to 18 ft. lbs. (25 Nm).
  20.  
  21. Install the valve lifters and the anti-rotation brackets.
  22.  
  23. Install the cylinder head.
  24.  
  25. Install the rocker arm cover.
  26.  
  27. Install the radiator.
  28.  
  29. Connect the negative battery cable and properly refill the engine cooling system.
  30.  

Diesel Engine

See Figure 4



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Fig. Fig. 4: Camshaft timing marks-2.2L diesel engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the crankcase. Remove the oil pan and the oil pump.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the timing belt cover, the timing belt, the camshaft sprocket.
  2.  
  3. Remove the rocker arm assembly, the pushrods and the valve lifters; be sure to keep the parts in order for reinstallation purposes.
  4.  
  5. Remove the camshaft retainer-to-engine bolts and the retainer. Using a small prybar, pry the oil seal from the cylinder block.
  6.  
  7. Screw a bolt into the camshaft and carefully remove the camshaft from the front of the engine; be careful not to damage the bearing surfaces.
  8.  
  9. Inspect the camshaft for wear, scoring and/or damage; if necessary, replace it.
  10.  

To install:
  1. Lubricate the camshaft with engine oil and insert it into the front of the engine.
  2.  
  3. Using a new oil seal, lubricate the seal lips with engine oil and install it into the engine.
  4.  
  5. Install the camshaft retainer and the camshaft sprocket.
  6.  
  7. Install the oil pump and the oil pan.
  8.  
  9. Install the valve lifters, the pushrods and the rocker arm assembly.
  10.  
  11. Install and adjust the timing belt. Install the timing belt cover.
  12.  
  13. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke and adjust the valve lash.
  14.  
  15. To complete the installation, reverse the removal procedures.
  16.  
  17. Refill the cooling system and the crankcase.
  18.  
  19. Connect the negative battery cable. Start the engine, allow it to reach normal operating temperatures.
  20.  
  21. Check and/or adjust the idle speed and timing.
  22.  

2.3L and 2.6L Engines

Removal of the camshaft involves replacement of the timing belt and rocker arm assembly. Review those procedures first before proceeding further. It is not possible to replace the camshaft without completely disassembling the front cover, due to the need to align the timing belt marks on both the camshaft and crankshaft. The timing belt should be replaced any time the camshaft is serviced.

  1. Disconnect the negative battery cable.
  2.  
  3. Rotate the crankshaft to position the No. 4 cylinder on the TDC of its compression stroke.
  4.  
  5. Remove the distributor cap and move it aside. Matchmark the rotor to the distributor housing and the distributor housing to the engine. Remove the distributor.
  6.  
  7. Remove the rocker arm cover, the timing belt cover and the timing belt. Refer to procedures in the section.
  8.  
  9. Remove the rocker arm assembly-to-cylinder head bolts, the rocker arm assembly and the camshaft. If necessary, remove the camshaft sprocket-to-camshaft bolt and the sprocket.
  10.  

To install:
  1. Lubricate the camshaft with engine oil and position it onto the cylinder head.
  2.  
  3. Install the rocker arm assembly and torque the bolts to bolts to 6 ft. lbs. (8 Nm) and the nuts to 16 ft. lbs. (22 Nm).
  4.  
  5. Align the timing marks and install the timing belt.
  6.  
  7. Using a new gasket, install the rocker arm cover.
  8.  
  9. Install the timing belt cover.
  10.  
  11. Align the matchmarks and install the distributor to the cylinder head.
  12.  
  13. To complete the installation, reverse the removal procedures.
  14.  
  15. With the timing marks aligned, start the engine, then, check and/or adjust the engine timing.
  16.  

2.8L and 3.1L Engines

See Figure 5



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Fig. Fig. 5: Replacing the camshaft-2.8L and 3.1L engines

Removal of the camshaft involves replacement of the timing chain assembly and removal of the radiator and usually front grille. Review those procedures first before proceeding further. If replacing the camshaft you should always install all new hydraulic lifters, and a new timing chain and gear set.

Use long bolts threaded into the camshaft to help remove the shaft without damaging the camshaft bearings. Remove the camshaft slowly while supporting the weight with the long bolt.

  1. Relieve the fuel pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the timing cover and the camshaft sprocket.
  4.  
  5. Remove the upper fan shroud and the radiator.
  6.  
  7. Disconnect the fuel line(s), the accelerator linkage, the vacuum hoses and electrical connectors from the throttle body unit.
  8.  
  9. Remove the rocker arm covers.
  10.  
  11. Loosen the valves, rotate them 90° and remove the pushrods; be sure to keep them aligned so they may be installed in their original positions.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Using a hydraulic lifter removal tool, pull the valve lifters from the engine.
  16.  
  17. Using 3 long bolts, thread them into the camshaft holes. Grasp the bolts and carefully, pull the camshaft from the front of the engine.
  18.  

All the camshaft bearing journals are the same diameter; exercise care in removing the camshaft so the bearings do not become damaged.

To install:
  1. Lubricate the camshaft with engine oil and install it into the engine.
  2.  
  3. Using a hydraulic lifter installation tool, install the hydraulic lifters into the engine.
  4.  
  5. Using new gaskets and sealant, install the intake manifold.
  6.  
  7. Install the pushrods and the rocker arms.
  8.  
  9. Install the camshaft sprocket, the timing chain and the front cover; be sure the timing marks are aligned.
  10.  
  11. Adjust the valves.
  12.  
  13. Using new gaskets, install the rocker arm covers.
  14.  
  15. To complete the installation, reverse the removal procedures. Refill the cooling system.
  16.  
  17. Start the engine and allow it to reach normal operating temperatures. Check and/or adjust the timing.
  18.  

3.2L SOHC Engine
1992-95 VEHICLES

See Figures 6, 7, 8, 9, 10 and 11



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Fig. Fig. 6: Camshaft mounting bolts torque sequence-3.2L SOHC engine



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Fig. Fig. 7: Camshaft seal repair kit-3.2L SOHC engine



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Fig. Fig. 8: Camshaft removal sequence-3.2L SOHC engine



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Fig. Fig. 9: Apply sealant to the cylinder head where the camshaft mounts



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Fig. Fig. 10: Apply sealant to the camshaft mounting brackets



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Fig. Fig. 11: Accelerator cable adjustment-3.2L SOHC engine

Isuzu has issued a recall notice for 1993-94 Troopers equipped with 3.2L SOHC engines. This is campaign number 94V-094, and involves faulty camshaft end plugs. The plugs may dislodge from the cylinder heads and can cause rapid oil loss. Remember this when ordering parts; a service kit is available for affected vehicles.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the upper cooling fan shroud.
  6.  
  7. Remove the cooling fan assembly.
  8.  
  9. Disconnect the accelerator cable from the throttle body and remove it from the bracket.
  10.  
  11. Disconnect the canister vacuum hose from the vacuum pipe.
  12.  
  13. Disconnect the vacuum booster hose from the common chamber.
  14.  
  15. Disconnect the MAP sensor; Canister vacuum switching valve (VSV); Exhaust gas recirculation (VSV); Intake air temperature sensor and ground connectors.
  16.  
  17. Remove the spark plug wires from the cylinder head cover.
  18.  
  19. Remove the ignition control module assembly.
  20.  
  21. Remove the four bolts and the throttle body from the common chamber.
  22.  
  23. Disconnect the vacuum hoses from the throttle body.
  24.  
  25. Disconnect the positive crankcase ventilation hose from the common chamber.
  26.  
  27. Disconnect the fuel pressure control valve vacuum hose from the common chamber.
  28.  
  29. Disconnect the evaporative emission canister purge hose from the common chamber.
  30.  
  31. Remove the EGR valve assembly.
  32.  
  33. Remove the common chamber from the intake manifold.
  34.  
  35. Disconnect the fuel feed and return hoses from the fuel rail assembly.
  36.  
  37. Remove the accessory drive belts.
  38.  
  39. Remove the power steering pump.
  40.  
  41. Remove the fan pulley assembly.
  42.  
  43. Remove the crankshaft pulley and damper.
  44.  
  45. Remove the timing belt cover.
  46.  
  47. Remove the timing belt auto tensioner (pusher). The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.
  48.  
  49. Align the timing marks and remove the timing belt. After the timing marks are aligned, the engine must not be disturbed.
  50.  
  51. Remove the cylinder head cover(s).
  52.  
  53. Remove the camshaft pulley.
  54.  
  55. Remove the camshaft front plate.
  56.  
  57. Remove the camshaft mounting bracket bolts and the camshaft.
  58.  

To install:
  1. Install new camshaft seals and retaining plates onto the cylinder. Tighten the right camshaft seal retaining plate 6mm bolts to 65 inch lbs. (7 Nm). Tighten the left camshaft seal retaining plate 8mm bolts to 191 inch lbs. (21.5 Nm).
  2.  
  3. Apply sealant to the mounting surfaces on the cylinder head where the front and rear camshaft mounting brackets attach to the cylinder head.
  4.  
  5. Install the camshaft and mounting brackets. Torque the bolts in sequence to 69 inch lbs. (8 Nm) for the M6 bolts and 13 ft. lbs. (18 Nm) for the M8 bolts.
  6.  
  7. Install the front plate. Torque the bolts to 12 ft. lbs. (17 Nm).
  8.  
  9. Install the camshaft pulley. Torque the mounting bolts to 41 ft. lbs. (55 Nm).
  10.  
  11. Apply sealant to both sides of the front and rear camshaft mounting brackets and install the cylinder head cover(s). Torque the bolts to 69 inch lbs. (8 Nm). Do not overtighten the cylinder head covers: they crack very easily.
  12.  
  13. Install the timing belt.
  14.  
  15. Install the timing belt auto tensioner. Torque the mounting bolts to 13 ft. lbs. (18 Nm).
  16.  
  17. Rotate the crankshaft by hand to verify that the timing belt is aligned properly and there is no piston-to-valve interference.
  18.  
  19. Install the timing belt cover.
  20.  
  21. Install the oil cooler hoses and bracket.
  22.  
  23. Install the crankshaft pulley assembly. Torque the center bolt to 123 ft. lbs. (167 Nm).
  24.  
  25. Install the fan pulley assembly. Torque the mounting bolts to 16 ft. lbs. (22 Nm).
  26.  
  27. Install the power steering pump.
  28.  
  29. Install the accessory drive belts.
  30.  
  31. Connect the fuel hoses to the fuel rail assembly.
  32.  
  33. Install the common chamber. Torque the bolts and nuts to 17 ft. lbs. (24 Nm) in a crisscross pattern.
  34.  
  35. Install the EGR valve assembly. Torque the mounting bolts on the valve side to 69 inch lbs. (8 Nm) and the bolts on the exhaust side to 21 ft. lbs. (28 Nm).
  36.  
  37. Connect the evaporative emission canister purge hose.
  38.  
  39. Connect the fuel pressure control valve vacuum hose.
  40.  
  41. Connect the positive crankcase ventilation hose.
  42.  
  43. Install the throttle body assembly. Torque the mounting bolts to 14 ft. lbs. (19 Nm).
  44.  
  45. Connect the vacuum hoses to the throttle body.
  46.  
  47. Install the ignition control module and the spark plug wires.
  48.  
  49. Connect the MAP sensor; Canister vacuum switching valve (VSV); Exhaust gas recirculation (VSV); Intake air temperature sensor and ground connectors.
  50.  
  51. Connect the vacuum booster hose.
  52.  
  53. Connect the air vacuum hose.
  54.  
  55. Connect the accelerator cable. Adjust the accelerator cable by pulling the cable housing while closing the throttle valve and tightening the adjusting nut and screw cap by hand temporarily. Now loosen the adjusting nut by three turns and then tightening the screw cap. Make sure the throttle valve reaches the screw stop when the throttle is closed.
  56.  
  57. Install the cooling fan assembly and the upper fan shroud.
  58.  
  59. Install the air cleaner assembly.
  60.  
  61. Connect the negative battery cable.
  62.  

1996 VEHICLES

See Figures 6, 7, 8, 9, 10 and 11


CAUTION
Fuel injection systems remain under pressure even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and personal injury.

  1. Relieve the fuel system pressure:
    1. Remove the fuel filler cap.
    2.  
    3. Remove the fuel pump relay from the underhood relay box.
    4.  
    5. Start the engine and let it run until it stalls. Then, crank the engine for an additional 30 seconds.
    6.  
    7. Turn the ignition switch to the OFF position.
    8.  

  2.  
  3. Disconnect the negative battery cable and reinstall the fuel pump relay.
  4.  
  5. Drain the coolant into a sealable container.
  6.  
  7. Support the hood as far open as possible.
  8.  
  9. Remove the air intake duct and the air cleaner box.
  10.  
  11. Disconnect and remove the upper and lower radiator hoses. Catch any coolant that runs out.
  12.  
  13. Loosen and remove the power steering pump, A/C compressor, and alternator drive belts.
  14.  
  15. Remove the cooling fan and its pulley assembly.
  16.  
  17. Unbolt the power steering pump mounting bracket. Move the pump and bracket out of the way without disconnecting the hydraulic lines.
  18.  
  19. Disconnect the throttle cable from the throttle body linkage.
  20.  
  21. Label and disconnect the following vacuum hoses from the intake manifold chamber:
    1. PCV hose
    2.  
    3. EVAP canister vacuum hose
    4.  
    5. Brake booster hose
    6.  

  22.  
  23. Label and disconnect the following sensor connectors from the rear of the intake manifold chamber:
    1. Ignition control module connectors
    2.  
    3. Linear EGR valve
    4.  
    5. MAP sensor
    6.  
    7. EVAP purge valve
    8.  
    9. Throttle position sensor
    10.  
    11. Idle air control valve
    12.  
    13. Intake air temperature sensor
    14.  

  24.  
  25. Disconnect the EGR valve supply tube and bracket.
  26.  
  27. First, remove the throttle body, and then remove the intake manifold chamber.
  28.  
  29. Carefully clean any dirt from the fuel rail and fuel fittings.
  30.  
  31. Disconnect the fuel feed and return lines from the front of the fuel rail. Clean up any spilled fuel.
  32.  
  33. Remove the intake manifold gaskets. Be careful not to drop any pieces of the gaskets into the engine. Don't scratch or gouge the machined aluminum mating surfaces of the intake manifold and engine block.
  34.  
  35. Cover the intake openings with a sheet of plastic or clean shop towels to keep out dirt and foreign objects.
  36.  
  37. Label the ignition coil assemblies and disconnect them from the wiring harness. Remove the coil assemblies so they won't be damaged.
  38.  
  39. Unbolt the oil cooler line brackets from the timing belt covers.
  40.  
  41. Remove the upper timing belt covers.
  42.  
  43. Rotate the crankshaft to align the camshaft timing marks with the pointer dots on the back covers. When the timing marks are aligned, the No. 2 piston is at TDC/compression.
  44.  
  45. Remove the crankshaft pulley. Remove the lower timing belt cover.
  46.  
  47. Remove the pusher assembly (tensioner) from below the timing belt tensioner pulley. The pusher rod must always be facing upward to prevent oil leakage. Push the pusher rod in, and insert a wire pin into the hole to keep the pusher rod retracted.
  48.  
  49. Remove the timing belt.
  50.  


WARNING
If the timing belt is worn, damaged, or shows signs of oil or coolant contamination, it must be replaced.

  1. Loosen the valve cover bolts in a crisscross sequence. Remove the valve covers.
  2.  
  3. Remove the camshaft sprockets and back covers.
  4.  
  5. Loosen the camshaft holder bolts in a crisscross sequence to prevent warping.
  6.  
  7. Remove the camshaft and camshaft holders from the cylinder head.
  8.  
  9. Inspect the camshaft lobes and journals for signs of wear or damage.
  10.  

To install:
  1. Make sure all mating surfaces are clean and free of oil, coolant, or gasket residue.
  2.  
  3. Lubricate the camshaft lobes and journals with clean engine oil.
  4.  
  5. Apply a bead of sealant to the front and rear camshaft holder mating surfaces on the cylinder head.
  6.  
  7. Install the camshaft and holder assembly onto the cylinder head before the sealant cures. Install the camshaft holder bolts, but don't tighten them yet.
  8.  
  9. Use a crisscross sequence to tighten the camshaft holder bolts. Tighten the 8mm bolts to 13 ft. lbs. (18 Nm). Tighten the 6mm bolts to 6 ft. lbs. (8 Nm).
  10.  
  11. Use a seal driver to install a new camshaft seal.
  12.  
  13. Install the camshaft sprocket back covers and tighten their bolts to 12 ft. lbs. (17 Nm).
  14.  
  15. Install the camshaft sprockets so that the timing marks are aligned. Tighten the bolts to 46 ft. lbs. (64 Nm).
  16.  
  17. Apply a 2-3mm bead of sealant to the joint were the camshaft holders meet the cylinder head. Install the valve cover with a new gasket before the sealant cures.
  18.  
  19. Tighten the valve cover bolts to 6 ft. lbs. (8 Nm) in crisscross pattern.
  20.  
  21. Verify that the camshaft and crankshaft timing marks are properly aligned.
  22.  
  23. Install and tension the timing belt. Tighten the pusher bolts to 14 ft. lbs. (19 Nm).
  24.  
  25. Install the lower timing belt covers and tighten the bolts to 13 ft. lbs. (18 Nm). Install the crankshaft pulley. Tighten the pulley bolt to 123 ft. lbs. (167 Nm).
  26.  
  27. Install the upper timing belt covers and tighten the bolts to 13 ft. lbs. (18 Nm).
  28.  
  29. Fit the oil cooler line brackets onto the timing cover and tighten the bolts to 13 ft. lbs. (18 Nm).
  30.  
  31. Reconnect the fuel feed and return lines.
  32.  
  33. Install and reconnect the ignition coil assemblies.
  34.  
  35. Install the intake manifold chamber and throttle body with new gaskets. Tighten the nuts and bolts to 17 ft. lbs. (24 Nm).
  36.  
  37. Reconnect the throttle cable to the throttle body linkage.
  38.  
  39. Reconnect the EGR valve supply tube and bracket.
  40.  
  41. Reconnect the following vacuum to the intake manifold chamber:
    1. PCV hose
    2.  
    3. EVAP canister vacuum hose
    4.  
    5. Brake booster hose
    6.  

  42.  
  43. Reconnect the following sensor connectors to the rear of the intake manifold chamber:
    1. Ignition control module connectors
    2.  
    3. Linear EGR valve
    4.  
    5. MAP sensor
    6.  
    7. EVAP purge valve
    8.  
    9. Throttle position sensor
    10.  
    11. Idle air control valve
    12.  
    13. Intake air temperature sensor
    14.  

  44.  
  45. Install the power steering pump and mounting bracket.
  46.  
  47. Install the cooling fan and its pulley assembly.
  48.  
  49. Install and tension the alternator, A/C compressor, and power steering pump drive belts.
  50.  
  51. Install and reconnect the upper and lower radiator hoses.
  52.  
  53. Install the air cleaner box and air intake duct.
  54.  
  55. Verify that all fuel lines, vacuum and coolant hoses, and wiring harness have been reconnected.
  56.  
  57. Refill the engine with fresh coolant.
  58.  
  59. Crank the engine until it starts. A longer-than-normal starting time may be necessary due to air in the fuel lines. Check all fuel line connections for leaks.
  60.  
  61. Bleed any air from the cooling system.
  62.  
  63. Bleed the power steering system if necessary.
  64.  
  65. Check the throttle cable operation and adjustment.
  66.  
  67. Check the engine oil level and add if necessary.
  68.  

3.2L DOHC Engine

See Figures 12, 13, 14, 15 and 16



Click image to see an enlarged view

Fig. Fig. 12: Install a retainer on the chain tensioner and remove it after installation-3.2L (DOHC) engine



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Fig. Fig. 13: Apply sealant to the bracket mounting surface on the cylinder head-3.2L (DOHC) engine



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Fig. Fig. 14: Camshaft and chain timing marks-3.2L (DOHC) engine



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Fig. Fig. 15: Chain tensioner installed position-3.2L (DOHC) engine



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Fig. Fig. 16: Apply sealant to the camshaft mounting brackets-3.2L (DOHC) engine

Isuzu has issued a recall notice for 1993-94 Troopers equipped with 3.2L DOHC engines. This is campaign number 94V-094, and involves faulty camshaft end plugs. The plugs may dislodge from the cylinder heads and can cause rapid oil loss. Remember this when ordering parts: a service kit is available for affected vehicles.

  1. Relieve the fuel pressure:
    1. Remove the fuel filler cap.
    2.  
    3. Remove the fuel pump relay from the underhood relay box.
    4.  
    5. Start the engine and let it run until it stalls. Then, crank the engine for an additional 30 seconds.
    6.  
    7. Turn the ignition switch to the OFF position.
    8.  

  2.  
  3. Disconnect the negative battery cable. Install the fuel pump relay.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the upper cooling fan shroud.
  8.  
  9. Remove the cooling fan assembly.
  10.  
  11. Disconnect the accelerator cable from the throttle body and remove it from the bracket.
  12.  
  13. Disconnect the canister vacuum hose from the vacuum pipe.
  14.  
  15. Disconnect the vacuum booster hose from the common chamber.
  16.  
  17. Disconnect the following connectors:
    1. MAP sensor
    2.  
    3. Canister vacuum switching valve (VSV)
    4.  
    5. Exhaust gas recirculation (VSV)
    6.  
    7. Intake air temperature sensor
    8.  
    9. Ground cables
    10.  

  18.  
  19. Disconnect and label the spark plug wires.
  20.  
  21. Remove the ignition control module assembly with the spark plug wire attached.
  22.  
  23. Remove the four bolts to separate the throttle body from the common chamber.
  24.  
  25. Disconnect the vacuum hoses from the throttle body.
  26.  
  27. Disconnect the positive crankcase ventilation (PCV) hose from the common chamber.
  28.  
  29. Disconnect the fuel pressure control valve vacuum hose from the common chamber.
  30.  
  31. Disconnect the evaporative emission canister purge hose from the common chamber.
  32.  
  33. Remove the EGR valve assembly.
  34.  
  35. Remove the common chamber air duct.
  36.  
  37. Remove the common chamber from the intake manifold.
  38.  
  39. Disconnect the fuel feed and return hoses from the fuel rail assembly.
  40.  
  41. Remove the accessory drive belts.
  42.  
  43. Remove the power steering pump.
  44.  
  45. Remove the fan pulley assembly.
  46.  
  47. Remove the crankshaft pulley and damper.
  48.  
  49. Remove the oil cooler hoses and bracket.
  50.  
  51. Remove the timing belt cover.
  52.  
  53. Align the timing marks
  54.  
  55. Remove the timing belt auto tensioner (pusher). The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.
  56.  
  57. Remove the timing belt.
  58.  
  59. Remove the cylinder head covers.
  60.  
  61. Remove the camshaft pulley.
  62.  
  63. Remove the camshaft front plate.
  64.  
  65. Remove the camshaft mounting bracket bolts.
  66.  
  67. Remove the camshaft chain tensioner bolts.
  68.  
  69. Remove the camshafts with the timing chain and tensioner attached.
  70.  

To install:

Install a retainer on the chain tensioner to prevent the plunger from moving. Remove the retainer after installation.

  1. Apply sealant to the cylinder head mounting surface of the front and rear camshaft mounting brackets.
  2.  
  3. Apply clean engine oil to the camshaft journals, lobes, and sprockets.
  4.  
  5. Install the camshaft assembly with the chain and tensioner. Take care not to install the wrong tensioner, the left and right tensioners are different and they are marked accordingly. Make sure the timing marks on the camshaft chain sprockets are aligned with the timing marks on the chain links. Torque the camshaft holder mounting bolts to 87 inch lbs. (10 Nm).
  6.  
  7. Install the chain tensioner. Torque the bolts to 14 ft. lbs. (19 Nm).
  8.  
  9. Install new camshaft seals and retaining plates onto the cylinder. Tighten the rear camshaft seal retaining plate 6mm bolts to 70 inch lbs. (8 Nm). Tighten the front camshaft seal retaining bolts to 65 inch lbs. (7 Nm).
  10.  
  11. Install the camshaft pulley. Hold the camshaft with an open ended wrench to prevent it from turning and torque the pulley bolts to 41 ft. lbs. (55 Nm) for 1992-94 vehicles, or 46 ft. lbs. (63 Nm) for 1995 vehicles.
  12.  
  13. Apply sealant to both sides of the front and rear camshaft mounting brackets and install the cylinder head cover(s). Torque the bolts to 69 inch lbs. (8 Nm). Don't overtorque the bolts, as the head covers may crack.
  14.  
  15. Install the timing belt.
  16.  
  17. Install the timing belt auto tensioner. Torque the mounting bolts to 14 ft. lbs. (19 Nm).
  18.  
  19. Install the timing belt cover.
  20.  
  21. Install the oil cooler hoses and bracket.
  22.  
  23. Install the crankshaft pulley assembly. Torque the center bolt to 123 ft. lbs. (167 Nm).
  24.  
  25. Install the fan pulley assembly. Torque the mounting bolts to 16 ft. lbs. (22 Nm).
  26.  
  27. Install the power steering pump.
  28.  
  29. Install the accessory drive belts.
  30.  
  31. Connect the fuel hoses to the fuel rail assembly.
  32.  
  33. Install the common chamber. Torque the bolts and nuts to 17 ft. lbs. (24 Nm).
  34.  
  35. Install the common chamber air duct. Torque the nuts and bolts to 17 ft. lbs. (24 Nm).
  36.  
  37. Connect the ground cable.
  38.  
  39. Install the EGR valve assembly. Torque the mounting bolts on the valve side to 69 inch lbs. (8 Nm) and the bolts on the exhaust side to 21 ft. lbs. (28 Nm).
  40.  
  41. Connect the evaporative emission canister purge hose.
  42.  
  43. Connect the fuel pressure control valve vacuum hose.
  44.  
  45. Reconnect the fuel lines using new washers.
  46.  
  47. Connect the positive crankcase ventilation hose.
  48.  
  49. Install the throttle body assembly. Torque the mounting bolts to 14 ft. lbs. (19 Nm).
  50.  
  51. Connect the vacuum hoses to the throttle body.
  52.  
  53. Install the ignition control module and the spark plug wires.
  54.  
  55. Connect the MAP sensor; Canister Vacuum Switching Valve (VSV); Exhaust Gas Recirculation (EGR), the Intake air temperature sensor connectors; and ground cables.
  56.  
  57. Connect the vacuum booster hose.
  58.  
  59. Connect the air vacuum hose.
  60.  
  61. Connect the accelerator cable. Adjust the accelerator cable by pulling the cable housing while closing the throttle valve and tightening the adjusting nut and screw cap by hand temporarily. Now loosen the adjusting nut by three turns and then tightening the screw cap. Make sure the throttle valve reaches the screw stop when the throttle is closed.
  62.  
  63. Install the cooling fan assembly and the upper fan shroud.
  64.  
  65. Install the air cleaner assembly.
  66.  
  67. Connect the negative battery cable.
  68.  
  69. Start the engine and check for fuel leaks.
  70.  

INSPECTION



See Figures 17, 18 and 19



Click image to see an enlarged view

Fig. Fig. 17: Measuring camshaft lobe lift



Click image to see an enlarged view

Fig. Fig. 18: Measuring camshaft run-out



Click image to see an enlarged view

Fig. Fig. 19: Measuring camshaft straightness

Using solvent, degrease the camshaft and clean out all of the oil holes. Visually inspect the cam lobes and bearing journals for excessive wear. If a lobe is questionable, check all of the lobes as indicated. If a journal or lobe is worn, the camshaft MUST BE or replaced.

If a journal is worn, there is a good chance that the bearings or journals are worn and need replacement.

If the lobes and journals appear intact, place the front and rear journals in V-blocks and rest a dial indicator on the center journal. Rotate the camshaft to check the straightness. If deviation exceeds 0.001 in. (0.0254mm), replace the camshaft.

Check the camshaft lobes with a micrometer, by measuring the lobes from the nose to the base and again at 90° (see illustration). The lobe lift is determined by subtracting the second measurement from the first. If all of the exhaust and intake lobes are not identical, the camshaft must be reground or replace.

 
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