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

Cylinder Head

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REMOVAL & INSTALLATION



1.8L and 2.0L Engines

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Cylinder head bolt torque sequence-1.8L and 2.0L engines



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Fig. Fig. 2: Locking the timing chain adjuster-1.8L engine shown



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Fig. Fig. 3: Keep the timing sprocket attached to the chain while aligning or removing. A piece of mechanics wire may be helpful



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Fig. Fig. 4: Locking the timing chain adjuster-2.0L engine shown



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Fig. Fig. 5: Push in on the automatic adjuster shoe (1) and lock it in the retracted position by releasing lever (2)-2.0L engine

  1. Disconnect the negative battery cable and drain the engine coolant. Remove the rocker cover.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the EGR pipe clamp bolt at the rear of the cylinder head.
  2.  
  3. Raise and support the vehicle safely. Disconnect the exhaust pipe at the exhaust manifold.
  4.  
  5. Lower the vehicle.
  6.  
  7. Disconnect the heater hoses at the intake manifold and at the rear of the cylinder head. Remove the air conditioning compressor and/or power steering pump with hoses attached and support them aside.
  8.  
  9. Disconnect the accelerator linkage and fuel line at the carburetor. Disconnect and label the electrical connections, spark plug wires and vacuum lines at the cylinder head.
  10.  
  11. Rotate the engine until the No. 4 cylinder is in the firing position. Remove the distributor cap and mark the rotor to housing relationship. Remove distributor and the fuel pump.
  12.  
  13. Lock the timing chain adjuster by depressing and turning the automatic adjuster side pin 90° clockwise.
  14.  
  15. Remove the timing sprocket-to-camshaft bolt and remove the sprocket from the camshaft.
  16.  

Keep the sprocket on the chain damper and chain.

  1. Disconnect the AIR hose and the check valve at the exhaust manifold.
  2.  
  3. Remove the cylinder head to timing cover bolts.
  4.  
  5. Starting with the outer bolts and working inward, remove the cylinder head bolts.
  6.  
  7. Remove the cylinder head, intake and exhaust manifold as a unit. Remove all accessories if the manifold has to be serviced.
  8.  

To install:
  1. Clean the gasket mating surfaces with scraper and solvent. Check the cylinder head and block for warpage using a straightedge and feeler gauge. Refer to Cylinder Head Inspection procedure in this section.
  2.  
  3. Use a new gasket and install the cylinder head on the engine.
  4.  
  5. Torque the bolts to specifications. Refer to the Torque Specifications chart earlier in this section.
  6.  
  7. Install the timing chain by performing the following procedures:
    1. Install the timing sprocket and pinion gear with the groove side toward the front cover. Align the key grooves with the key on the crankshaft, then drive into position.
    2.  
    3. Confirm that the No. 1 piston is at TDC. If not, turn the crankshaft so the key is turned toward the cylinder head side (No. 1 and No. 4 pistons at top dead center).
    4.  
    5. Install the timing chain by aligning the mark plate on the chain with the mark on the crankshaft timing sprocket. The side of the chain with the mark plate is on the front side and the side of the chain with the most links between the mark plates is on the chain guide side.
    6.  
    7. Install the camshaft timing sprocket so the mark side of the sprocket faces forward and so the triangular mark aligns with the chain mark plate.
    8.  

  8.  

Keep the timing chain engaged with the camshaft timing sprocket until the sprocket is installed on the camshaft.

  1. Install the front cover assembly, using a new gasket and sealer.
  2.  
  3. Connect the AIR hose and the check valve at the exhaust manifold.
  4.  
  5. Connect the accelerator linkage and fuel line to the carburetor. Connect the electrical connections, the spark plug wires and the vacuum lines.
  6.  
  7. Connect the heater hoses to the intake manifold and the rear of the cylinder head. Install the air conditioner compressor and/or power steering pump.
  8.  
  9. Connect the exhaust pipe to the exhaust manifold.
  10.  
  11. Install the EGR pipe clamp bolt to the rear of the cylinder head.
  12.  
  13. Install the rocker arm cover and connect the negative battery cable.
  14.  
  15. Refill the engine with coolant. Start the engine and check for leaks.
  16.  

Diesel Engine

See Figures 6, 7 and 8



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Fig. Fig. 6: Rocker arm shaft torque sequence-diesel engine



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Fig. Fig. 7: Head gasket positioning-diesel engine



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Fig. Fig. 8: Cylinder head bolt torque sequence-diesel engine

  1. Relieve the fuel pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the cooling fan assembly and the drive belt. Remove the alternator and bracket.
  2.  
  3. Remove the upper radiator hose and heater hose(s).
  4.  
  5. Remove the air cleaner and intake duct.
  6.  
  7. Label and disconnect the necessary vacuum hoses and electrical connectors.
  8.  
  9. Remove the fuel injector pipe, the clip and the nozzle holder assembly.
  10.  
  11. Remove the glow plugs and sensing resister.
  12.  
  13. If equipped with a turbocharger, remove the turbocharger cover and the turbocharger.
  14.  
  15. Remove the intake and exhaust manifolds from the cylinder head; discard the gaskets.
  16.  
  17. Remove the rocker arm cover, the valve tappet chamber cover and rocker oil feed pipe.
  18.  
  19. Back off the rocker arm adjustments. Remove the rocker arm assembly-to-cylinder head bolts and the rocker arm assembly.
  20.  
  21. Remove the pushrods and keep them in order for reinstallation purposes.
  22.  
  23. Remove the cylinder head-to-engine bolts, a little at a time, by reversing the torquing sequence. Remove the cylinder head; it may be necessary to use a mallet to tap the cylinder head loose from the engine.
  24.  
  25. Match the old gasket to the new cylinder head gasket and clean the gasket mounting surfaces.
  26.  

To install:
  1. Using a new gasket, position it onto the engine with the work TOP facing upwards.
  2.  
  3. Refill the turbocharger with clean engine oil before installation.
  4.  
  5. Install the cylinder head onto the engine. Lubricate the cylinder head bolts with engine oil and torque them, in sequence, using the following procedure:
  6.  

Turbocharged Engine:


1st step: 33-40 ft. lbs. (45-54 Nm)
 
2nd step: 120-150°
 

Non-Turbocharged Engine:



1st step: 40-47 ft. lbs. (54-63 Nm)
 
2nd step: 54-61 ft. lbs. (74-81 Nm) for a new bolt or 61-69 ft. lbs. (81-95 Nm) for a used bolt
 

  1. Install the pushrods and make sure they are positioned in the tappets.
  2.  
  3. Install the rocker arm assembly and torque the rocker arm-to-cylinder head bolts to 10-17 ft. lbs. (14-24 Nm) Adjust the valve lash.
  4.  
  5. Using new gaskets, reverse the removal procedures.
  6.  
  7. Refill the cooling system. Connect the negative battery cable. Start the engine and check for leaks.
  8.  

2.2L Gasoline Engine

See Figure 9



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Fig. Fig. 9: Cylinder head bolt torque sequence-2.2L gasoline engine

  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system, then disconnect the air duct from the air inlet.
  4.  
  5. Disconnect the upper radiator hose, then remove the upper fan shroud.
  6.  
  7. Remove the radiator assembly, then remove the lower fan shroud.
  8.  
  9. Remove the fan assembly, then remove the serpentine drive belt.
  10.  
  11. Remove the water pump pulley.
  12.  
  13. Disconnect the heater hose form the intake manifold and the thermostat housing, then remove the thermostat housing.
  14.  
  15. Remove the alternator support brace and disengage the alternator wiring. See the Intake Manifold procedure, earlier in the section.
  16.  
  17. If equipped, remove the A/C compressor with brackets, then position them aside. DO NOT disconnect the refrigerant lines, but be careful not to kink and damage them.
  18.  
  19. Disconnect and reposition the accessory bracket along with the alternator and P/S pump still attached. Be careful not to damage the steering pump lines.
  20.  
  21. Disconnect the throttle cable and cable support linkage, then disconnect the heater hose from the water pump.
  22.  
  23. Remove the oil fill tube, then disconnect the exhaust pipe and the oxygen sensor.
  24.  
  25. Remove the exhaust manifold bolts, then remove the manifold. Refer to the Exhaust Manifold procedure, earlier in this section.
  26.  
  27. Tag and disconnect both the electrical wiring and the vacuum hoses from the upper intake manifold. See the Intake Manifold procedure, earlier in this section.
  28.  
  29. Remove the upper intake manifold, then tag and disconnect the wiring from the lower intake manifold.
  30.  
  31. Disconnect the fuel lines, then tag and disconnect the spark plug wires.
  32.  
  33. Remove the lower intake manifold from the engine.
  34.  
  35. Remove the rocker arm cover from the cylinder head.
  36.  
  37. Remove the rocker arms and pushrods.
  38.  
  39. Disconnect the engine lift bracket from the rear of the engine.
  40.  
  41. Remove the cylinder head bolts and studs, then carefully lift the cylinder head from the engine.
  42.  

To install:
  1. Carefully clean and inspect the gasket mounting surfaces.
  2.  

The gasket surfaces on both the head and block must be clean of any foreign matter and free of nicks or heavy scratches. The cylinder bolt threads in the block and thread on the bolts must be cleaned (dirt will affect the bolt torque).

  1. Place a new gasket over the dowel pins (DO NOT use any sealer on the gasket), then position the cylinder head over the gasket and dowels.
  2.  
  3. Apply a coating of GM-1052080 or equivalent sealer to the cylinder head bolt threads. Install the cylinder head bolts (within 15 minutes of sealer application), then tighten them in the proper sequence first to a torque of 46 ft. lbs. (63 Nm) for long bolts or to 43 ft. lbs. (58 Nm) for short bolts and then tighten all bolts an additional 90 degree turn using a torque angle meter.
  4.  
  5. Install the engine lift bracket.
  6.  
  7. Install the rocker arms and pushrods.
  8.  
  9. Install the rocker arm cover.
  10.  
  11. Install the lower intake manifold. Refer to the procedure earlier in this section for specifications.
  12.  
  13. Connect the spark plug wires and the fuel lines.
  14.  
  15. Engage the wiring to the lower intake manifold.
  16.  
  17. Install the upper intake manifold. Refer to the procedure earlier in this section for specifications.
  18.  
  19. Connect the vacuum hoses and electrical wiring to the upper intake, as tagged during removal.
  20.  
  21. Install the oil fill tube assembly.
  22.  
  23. Install the exhaust manifold, then connect the exhaust pipe and oxygen sensor.
  24.  
  25. Connect the heater hose to the water pump, then connect the throttle cable support and throttle cable.
  26.  
  27. Install the accessory support bracket and components.
  28.  
  29. If equipped, reposition and secure the A/C compressor.
  30.  
  31. Install the power steering support brace and the alternator support brace. Engage the alternator wiring.
  32.  
  33. Install the thermostat housing, then connect the heater hose to the housing.
  34.  
  35. Install the water pump pulley and the serpentine drive belt.
  36.  
  37. Install the fan assembly, then install the radiator and the lower fan shroud.
  38.  
  39. Install the upper fan shroud, then connect the upper radiator hose.
  40.  
  41. Connect the air inlet duct work, then connect the negative battery cable.
  42.  
  43. Properly refill the engine cooling system and check for leaks.
  44.  

2.3L Engine

See Figures 10, 11, 12, 13, 14 and 15



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Fig. Fig. 10: Cylinder head removal sequence-2.3L and 2.6L engines



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Fig. Fig. 11: Rocker arm shaft bolt removal sequence-2.3L and 2.6L engines



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Fig. Fig. 12: Cylinder head bolt removal sequence-2.3L and 2.6L engines



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Fig. Fig. 13: Cylinder head gasket TOP mark must face up-2.3L shown



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Fig. Fig. 14: Cylinder head bolt tightening sequence-2.3L and 2.6L engines



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Fig. Fig. 15: Rocker arm shaft tightening sequence-2.3L and 2.6L engines

  1. Disconnect negative battery cable and drain cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Rotate the engine until the engine is at TDC on the compression stroke of the No. 1 cylinder, make sure timing mark is on the scale. Remove distributor cap and mark the distributor rotor to housing position and housing to cylinder head. Remove the distributor hold down bolt and remove the distributor.
  2.  
  3. Disconnect radiator inlet and outlet hoses and remove the radiator.
  4.  
  5. Remove the alternator and the air conditioner drive belts. Remove engine fan.
  6.  
  7. Remove the crankshaft pulley center bolt and remove the pulley and hub assembly.
  8.  
  9. Remove the air pump belt and move the air pump out of the way. Remove the air conditioning compressor and lay it to one side (if equipped with air conditioning). Remove the compressor mounting bracket.
  10.  
  11. Remove the water pump pulley. Remove the top section of the front cover and the water pump.
  12.  
  13. Remove the lower section of the front cover.
  14.  
  15. Remove the tension spring. Loosen the top bolt of the tension pulley and draw the tension pulley fully to the water pump side.
  16.  
  17. Remove the timing belt.
  18.  
  19. Remove cam cover.
  20.  
  21. Sequentially loosen and remove the rocker arm shaft tightening nuts from the outermost one and remove the rocker arm shaft with the bracket as an assembly.
  22.  
  23. Raise vehicle and disconnect the exhaust pipe at the exhaust manifold. On turbocharged model disconnect exhaust pipe from wastegate manifold and remove control cable for turbocharger.
  24.  
  25. Lower vehicle disconnect all lines, hoses, electrical connections and spark plug wires.
  26.  

Tag all wires and hoses before disconnecting them from the engine.

  1. Disconnect the accelerator linkage, on turbocharged model remove engine wiring harness assembly from fuel injectors and fuel line from fuel injector pipe.
  2.  
  3. Remove the cylinder head bolts using an extension bar with socket. Remove bolts in progressive sequence, beginning with the outer bolts.
  4.  

Use light oil to free frozen bolts.

  1. With the aid of an assistant, remove the cylinder head, intake and exhaust manifolds as an assembly.
  2.  

To install:
  1. Clean all gasket material from the cylinder head and block surfaces. Check for nicks or heavy scratches on the mating surfaces.
  2.  
  3. Cylinder bolt threads in the block and threads on the bolts must be cleaned. Dirt will affect head torque.
  4.  
  5. Match up the old gasket with the new gasket to make sure it is an exact fit.
  6.  
  7. Install the gasket and cylinder head with the help of an assistant. Torque in sequence and 2 steps first step 57 ft. lbs. (76 Nm) and second step 72 ft. lbs. (96 Nm).
  8.  
  9. Connect the accelerator linkage, on turbocharged model install engine wiring harness assembly to fuel injectors and fuel line to fuel injector pipe.
  10.  
  11. Connect all lines, hoses, electrical connections and spark plug wires.
  12.  
  13. Raise vehicle and connect the exhaust pipe at the exhaust manifold. On turbocharged model connect exhaust pipe to wastegate manifold and install control cable for turbocharger.
  14.  
  15. Sequentially install and torque the rocker arm shaft tightening nuts from the outermost one and install the rocker arm shaft with the bracket as an assembly. Refer to the appropriate illustration.
  16.  
  17. Install the rocker arm cover.
  18.  
  19. Install the timing belt.
  20.  
  21. Install the tension spring. Tighten the top bolt of the tension pulley.
  22.  
  23. Install the lower section of the front cover.
  24.  
  25. Install the water pump pulley. Install the top section of the front cover and the water pump.
  26.  
  27. Install the air pump and belt. Install the air conditioning compressor bracket and compressor.
  28.  
  29. Install the crankshaft pulley and center bolt.
  30.  
  31. Install the alternator and the air conditioner drive belts. Install engine fan.
  32.  
  33. Connect radiator inlet and outlet hoses and after installing the radiator.
  34.  
  35. Install the distributor, hold down bolt and cap.
  36.  
  37. Connect negative battery cable, refill the cooling system and check for leaks.
  38.  

2.6L Engine

See Figures 10, 11, 12, 13, 14 and 15

  1. Relieve the fuel pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the drive belts from the power steering pump, the air pump, the air conditioning compressor (if equipped) and the cooling fan.
  2.  
  3. Rotate the engine to position the No. 1 cylinder on TDC.
  4.  
  5. Remove the distributor cap, high tension cables and the distributor.
  6.  
  7. Remove the exhaust manifold-to-exhaust pipe bolts.
  8.  
  9. Label and disconnect the electrical connectors and vacuum hoses which may be in the way.
  10.  
  11. Remove the coolant hoses, the radiator and the cooling fan assembly.
  12.  
  13. Remove the crankshaft pulley bolt and the pulley.
  14.  
  15. Remove the upper and lower timing belt covers, the tension spring and the timing belt.
  16.  
  17. Remove the camshaft pulley bolt, the pulley and the camshaft boss.
  18.  
  19. Remove the timing belt guide plate and the cylinder head front plate.
  20.  
  21. Remove the rocker arm cover and gasket.
  22.  
  23. Remove the cylinder head-to-engine bolts, the cylinder head and gasket.
  24.  
  25. Clean the gasket mounting surfaces.
  26.  

To install:
  1. Using a new gasket, install the cylinder head and torque the bolts, in sequence to 57 ft. lbs. (76 Nm) in the 1st step and to 65-79 ft. lbs. (88-108 Nm) in the final step.
  2.  
  3. Install the camshaft pulley.
  4.  
  5. Using a new gasket, install the rocker arm cover.
  6.  
  7. Align the camshaft pulley mark with the mark on the front plate. Make sure the keyway on the crankshaft if facing upward, aimed at the pointer on the engine block.
  8.  
  9. Install the timing belt in the following order: crankshaft pulley, the oil pump pulley, the camshaft and the tensioner.
  10.  
  11. Install the timing belt covers, using a new gasket.
  12.  
  13. Install the crankshaft pulley.
  14.  
  15. Install the cooling fan assembly, the radiator and the coolant hoses.
  16.  
  17. Connect the electrical connectors and vacuum hoses.
  18.  
  19. Install the exhaust manifold-to-exhaust pipe bolts.
  20.  
  21. Install the distributor, the distributor cap, and the high tension cables.
  22.  
  23. Install the drive belts to the power steering pump, the air pump, the air conditioning compressor (if equipped) and the cooling fan.
  24.  
  25. Connect the negative battery cable. Refill the cooling system.
  26.  
  27. Start the engine and check for leaks.
  28.  

2.8L Engine

See Figures 16, 17, 18, 19, 20 and 21



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Fig. Fig. 16: Cylinder head bolt removal sequence-2.8L engine



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Fig. Fig. 17: Cylinder head bolt tightening sequence-2.8L engine



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Fig. Fig. 18: Loosen the cylinder head bolts by stages, in the reverse order of the tighten sequence-2.8L engine



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Fig. Fig. 19: Remember to cover the engine to keep old gasket material and dirt from getting inside-2.8L engine



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Fig. Fig. 20: Place cylinder head aside, Make certain all mating surfaces are clean of dirt and gasket material-2.8L engine



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Fig. Fig. 21: Removing the cylinder head gasket-2.8L engine

LEFT SIDE
  1. Relieve the fuel pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the intake manifold.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Disconnect the exhaust pipe from the exhaust manifold and remove the exhaust manifold-to-cylinder head bolts.
  6.  
  7. Remove the dipstick tube from the engine.
  8.  
  9. Lower the vehicle.
  10.  
  11. Loosen the rocker arm nuts, turn the rocker arms and remove the pushrods; keep the pushrods in the same order as removed.
  12.  
  13. Remove the cylinder head bolts in stages and in the reverse order of torquing.
  14.  
  15. Remove the cylinder head; do not pry on the head to loosen it.
  16.  
  17. Clean the gasket mounting surfaces.
  18.  

To install:
  1. Position a new cylinder head gasket over the dowel pins with the words This Side Up facing upwards. Carefully, guide the cylinder head into place.
  2.  
  3. Install the pushrods; make sure the lower ends are in the lifter heads. Torque the rocker arm nuts to 14-20 ft. lbs. (20-27 Nm).
  4.  
  5. Install the intake manifold.
  6.  
  7. Install the dipstick tube to the engine.
  8.  
  9. Install the exhaust manifold-to-cylinder head bolts and the exhaust pipe-to-exhaust manifold nuts.
  10.  
  11. Refill the cooling system. Start the engine and check for leaks.
  12.  

RIGHT SIDE
  1. Relieve the fuel pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the intake manifold.
  2.  
  3. If equipped, remove the cruise control servo bracket, the air management valve and hose.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the exhaust pipe from the exhaust manifold and remove the exhaust manifold-to-cylinder head bolts.
  8.  
  9. Remove the exhaust pipe at crossover, the crossover and the heat shield, if equipped.
  10.  
  11. Lower the vehicle.
  12.  
  13. Label and disconnect the electrical wiring and vacuum hoses that may interfere with the removal of the right cylinder head.
  14.  
  15. Loosen the rocker arm nuts, turn the rocker arms and remove the pushrods; keep the pushrods in the same order as removed.
  16.  
  17. Remove the cylinder head bolts in stages and in the reverse order of torquing.
  18.  
  19. Remove the cylinder head; do not pry on the head to loosen it.
  20.  
  21. Clean the gasket mounting surfaces.
  22.  

To install:
  1. Position a new cylinder head gasket over the dowel pins with the words This Side Up facing upwards. Carefully, guide the cylinder head into place.
  2.  
  3. Install the pushrods; make sure the lower ends are in the lifter heads. Torque the rocker arm nuts to 14-20 ft. lbs. (20-27 Nm).
  4.  
  5. Install the intake manifold.
  6.  
  7. Install the exhaust pipe at crossover, the crossover and the heat shield, if equipped.
  8.  
  9. Install the exhaust manifold-to-cylinder head bolts and the exhaust pipe-to-exhaust manifold nuts.
  10.  
  11. Connect the electrical wiring and vacuum hoses to the right cylinder head.
  12.  
  13. If equipped, install the cruise control servo bracket, the air management valve and hose.
  14.  
  15. Refill the cooling system. Start the engine and check for leaks.
  16.  

3.1L Engine

See Figures 22 and 23



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Fig. Fig. 22: Cylinder head bolt removal sequence-3.1L engine



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Fig. Fig. 23: Cylinder head bolt tightening sequence-3.1L engine

LEFT SIDE
  1. Relieve the fuel pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the exhaust pipe from the exhaust manifold and remove the exhaust manifold-to-cylinder head bolts.
  8.  
  9. Remove the dipstick tube from the engine.
  10.  
  11. Lower the vehicle.
  12.  
  13. Loosen the rocker arm nuts, turn the rocker arms and remove the pushrods; keep the pushrods in the same order as removed.
  14.  
  15. Remove the cylinder head bolts in stages and in the reverse order of torquing.
  16.  
  17. Remove the cylinder head; do not pry on the head to loosen it.
  18.  
  19. Clean the gasket mounting surfaces thoroughly.
  20.  

To install:
  1. Position a new cylinder head gasket over the dowel pins with the words This Side Up facing upwards. Carefully, guide the cylinder head into place.
  2.  
  3. Torque the cylinder head bolts in sequence to 41 ft. lbs. (55 Nm) then go back and turn each bolt an additional 90 degrees.
  4.  
  5. Install the pushrods; make sure the lower ends are in the lifter heads. Torque the rocker arm nuts to 14-20 ft. lbs. (20-27 Nm).
  6.  
  7. Install the intake manifold.
  8.  
  9. Install the dipstick tube to the engine.
  10.  
  11. Install the exhaust manifold-to-cylinder head bolts and the exhaust pipe-to-exhaust manifold nuts.
  12.  
  13. Refill the cooling system. Start the engine and check for leaks.
  14.  

RIGHT SIDE
  1. Relieve the fuel pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the intake manifold.
  4.  
  5. If equipped, remove the cruise control servo bracket, the air management valve and hose.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Disconnect the exhaust pipe from the exhaust manifold and remove the exhaust manifold-to-cylinder head bolts.
  10.  
  11. Remove the exhaust pipe at crossover, the crossover and the heat shield, if equipped.
  12.  
  13. Lower the vehicle.
  14.  
  15. Label and disconnect the electrical wiring and vacuum hoses that may interfere with the removal of the right cylinder head.
  16.  
  17. Loosen the rocker arm nuts, turn the rocker arms and remove the pushrods; keep the pushrods in the same order as removed.
  18.  
  19. Remove the cylinder head bolts in stages and in the reverse order of torquing.
  20.  
  21. Remove the cylinder head; do not pry on the head to loosen it.
  22.  
  23. Clean the gasket mounting surfaces thoroughly.
  24.  

To install:
  1. Position a new cylinder head gasket over the dowel pins with the words This Side Up facing upwards. Carefully, guide the cylinder head into place.
  2.  
  3. Torque the cylinder head bolts in sequence to 41 ft. lbs. (55 Nm) then go back and turn each bolt an additional 90 degrees.
  4.  
  5. Install the pushrods; make sure the lower ends are in the lifter heads. Torque the rocker arm nuts to 14-20 ft. lbs. (20-27 Nm).
  6.  
  7. Install the intake manifold.
  8.  
  9. Install the exhaust pipe at crossover, the crossover and the heat shield, if equipped.
  10.  
  11. Install the exhaust manifold-to-cylinder head bolts and the exhaust pipe-to-exhaust manifold nuts.
  12.  
  13. Connect the electrical wiring and vacuum hoses to the right cylinder head.
  14.  
  15. If equipped, install the cruise control servo bracket, the air management valve and hose.
  16.  
  17. Refill the cooling system. Start the engine and check for leaks.
  18.  

3.2L Engine
1993-95 VEHICLES

See Figures 24, 25, 26, 27 and 28



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Fig. Fig. 24: Camshaft seal replacement parts-3.2L engine



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Fig. Fig. 25: Cylinder head removal sequence-1993-95 3.2L engine



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Fig. Fig. 26: Cylinder head bolt removal sequence-1993-95 3.2L engine



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Fig. Fig. 27: Cylinder head bolt torque sequence-1993-95 3.2L engine



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Fig. Fig. 28: Accelerator cable adjustment-1993-95 3.2L engine

Isuzu has issued a recall notice for 1993-94 Rodeos equipped with 3.2L 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. Matchmark the hood hinge to the hood and remove the hood.
  2.  
  3. Relieve the fuel system pressure and disconnect the negative battery cable.
  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 the bracket.
  12.  
  13. Disconnect the canister vacuum hose from the vacuum pipe.
  14.  
  15. Disconnect the air vacuum hose from the common chamber.
  16.  
  17. Disconnect the vacuum booster hose from the common chamber.
  18.  
  19. Disconnect the MAP sensor; Canister vacuum switching valve (VSV); Exhaust gas recirculation (VSV); Intake air temperature sensor and ground connectors.
  20.  
  21. Remove the spark plug wires from the cylinder head cover.
  22.  
  23. Remove the ignition control module assembly.
  24.  
  25. Remove the four bolts and the throttle body from the common chamber.
  26.  
  27. Disconnect the vacuum hoses from the throttle body.
  28.  
  29. Disconnect the positive crankcase ventilation hose from the common chamber.
  30.  
  31. Disconnect the fuel pressure control valve vacuum hose from the common chamber.
  32.  
  33. Disconnect the evaporative emission canister purge hose from the common chamber.
  34.  
  35. Remove the EGR valve assembly.
  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. Disconnect the connectors to the fuel injectors and the thermo sensor.
  42.  
  43. Remove the intake manifold.
  44.  
  45. Remove the engine coolant manifold by removing the heater hose and four mounting bolts.
  46.  
  47. Remove the accessory drive belts.
  48.  
  49. Remove the power steering pump.
  50.  
  51. Remove the fan pulley assembly.
  52.  
  53. Remove the crankshaft pulley and damper.
  54.  
  55. Remove the oil cooler hoses and bracket on the timing belt cover.
  56.  
  57. Remove the timing belt cover.
  58.  
  59. Align the timing marks.
  60.  
  61. Remove the timing belt auto tensioner (pusher). The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.
  62.  
  63. Remove the timing belt.
  64.  
  65. Remove the cylinder head cover.
  66.  
  67. Remove the power steering pump bracket.
  68.  
  69. Remove the front exhaust pipes from the exhaust manifolds.
  70.  
  71. Remove the dipstick tube bracket from the cylinder head.
  72.  


WARNING
The cylinder head and engine block must be at room temperature before removing the cylinder head.

  1. Remove the cylinder head bolts in sequence, gradually and in two steps.
  2.  
  3. Remove the cylinder head.
  4.  

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. Tighten the left camshaft seal retaining plate 8mm bolts to 191 inch lbs.
  2.  
  3. Thoroughly clean the cylinder head and engine block sealing surfaces.
  4.  
  5. Place a new head gasket on the engine block and carefully position the cylinder head on top of the new gasket.
  6.  

Do not reuse or apply oil to the cylinder head bolts.

  1. Install new cylinder head bolts and torque them in sequence to 47 ft. lbs. (64 Nm) for the M11 bolts and 15 ft. lbs. (21 Nm) for the M8 bolts.
  2.  
  3. Install the dipstick tube bracket to the cylinder head.
  4.  
  5. Connect the front exhaust pipes to the exhaust manifolds. Tighten the exhaust bolts to 48 ft. lbs. (67 Nm).
  6.  
  7. Install the power steering pump bracket. Torque the mounting bolts to 34 ft. lbs. (46 Nm).
  8.  
  9. Install the cylinder head covers.
  10.  
  11. Install the timing belt and the auto tensioner (pusher). Torque the mounting bolt to 14 ft. lbs. (19 Nm).
  12.  
  13. Install the timing belt cover and oil cooler hoses and bracket.
  14.  
  15. Install the crankshaft pulley. Torque the center bolt to 123 ft. lbs. (167 Nm).
  16.  
  17. Install the fan pulley assembly.
  18.  
  19. Install the power steering pump.
  20.  
  21. Install the accessory drive belts.
  22.  
  23. Install the engine coolant manifold and the heater hose.
  24.  
  25. Install the intake manifold. Torque the nuts and bolts to 17 ft. lbs. (24 Nm) in a crisscross pattern.
  26.  
  27. Install the fuel injector connectors and the fuel hoses to the fuel rail.
  28.  
  29. Install the common chamber. Torque the nuts and bolts to 17 ft. lbs. (24 Nm).
  30.  
  31. 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).
  32.  
  33. Connect the evaporative emission canister purge hose.
  34.  
  35. Connect the fuel pressure control valve vacuum hose.
  36.  
  37. Connect the positive crankcase ventilation hose.
  38.  
  39. Install the throttle body assembly. Torque the mounting bolts to 14 ft. lbs. (19 Nm).
  40.  
  41. Connect the vacuum hoses to the throttle body.
  42.  
  43. Install the ignition control module and the spark plug wires.
  44.  
  45. Connect the MAP sensor; Canister vacuum switching valve (VSV); Exhaust gas recirculation (VSV); Intake air temperature sensor and ground connectors.
  46.  
  47. Connect the vacuum booster hose.
  48.  
  49. Connect the air vacuum hose.
  50.  
  51. 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.
  52.  
  53. Install the cooling fan assembly and the upper fan shroud.
  54.  
  55. Install the air cleaner assembly.
  56.  
  57. Connect the negative battery cable.
  58.  
  59. Refill and bleed the cooling system.
  60.  
  61. Refill and bleed the power steering pump if necessary.
  62.  
  63. Refill the engine with fresh oil.
  64.  
  65. Run the engine and check for leaks and proper compression.
  66.  

1996 VEHICLES

See Figures 29, 30 and 31



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Fig. Fig. 29: Cylinder head bolt removal sequence-1996 3.2L engine



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Fig. Fig. 30: Cylinder head bolt torque sequence-1996 3.2L engine



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Fig. Fig. 31: Throttle cable adjustment-1996 3.2L engine


WARNING
The cylinder head should be cool to the touch before it is removed. If the head bolts are loosened on a hot engine, the cylinder head may warp.

  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.  


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. Disconnect the negative battery cable and reinstall the fuel pump relay.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Disconnect the front exhaust pipes from the exhaust manifolds. If necessary, separate the front exhaust pipes from the crossover pipe. Label and disconnect the oxygen sensors.
  6.  
  7. Lower the vehicle.
  8.  
  9. Drain the coolant into a sealable container.
  10.  
  11. Use a felt-tipped marker to matchmark the hood hinge plates. Remove the hood.
  12.  
  13. Remove the air intake duct and the air cleaner box.
  14.  
  15. Disconnect and remove the upper and lower radiator hoses. Catch the coolant that runs out.
  16.  
  17. Loosen and remove the power steering pump, A/C compressor, and alternator drive belts.
  18.  
  19. Remove the cooling fan and its pulley assembly.
  20.  
  21. Unbolt the power steering pump mounting bracket. Move the pump and bracket out of the way without disconnecting the hydraulic lines.
  22.  
  23. Disconnect the throttle cable from the throttle body linkage.
  24.  
  25. 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.  

  26.  
  27. 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.  

  28.  
  29. Disconnect the EGR valve supply tube and bracket.
  30.  
  31. First, remove the throttle body, and then remove the intake manifold chamber.
  32.  
  33. Carefully clean any dirt from the fuel rail and fuel fittings.
  34.  
  35. Disconnect the fuel feed and return lines from the front of the fuel rail. Clean up any spilled fuel.
  36.  
  37. Label and disconnect the fuel injector wiring harness.
  38.  
  39. Remove the fuel injectors and lower intake manifold as an assembly. If desired, the fuel rail and injectors may be removed separately as an assembly.
  40.  
  41. 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.
  42.  
  43. Cover the intake openings with a sheet of plastic or clean shop towels to keep out dirt and foreign objects.
  44.  
  45. Label the ignition coil assemblies and disconnect them from the wiring harness. Remove the coil assemblies so they won't be damaged.
  46.  
  47. Unbolt the oil cooler line brackets from the timing belt covers.
  48.  
  49. 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.
  50.  
  51. Remove the crankshaft pulley. Remove the lower timing belt cover.
  52.  
  53. 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.
  54.  
  55. Remove the timing belt.
  56.  


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

  1. Disconnect the heater hoses from the engine; then, unbolt and remove the engine coolant manifold.
  2.  
  3. Unbolt the dipstick tube from the cylinder head.
  4.  
  5. Loosen the valve cover bolts in a crisscross sequence. Remove the valve covers.
  6.  
  7. Loosen the cylinder head bolts in a two-step crisscross pattern working from the outer bolts to those at the center of the head. First, partially loosen the 11mm bolts, then partially loosen the 8mm bolts. Finally loosen all the bolts and then remove them.
  8.  
  9. Remove the cylinder head. If it sticks, tap it with a wooden or plastic-faced mallet.
  10.  
  11. Remove the head gasket.
  12.  
  13. Inspect the cylinder head for cracking or warpage. Inspect the engine block for any signs of damage. Carefully clean the head gasket mating surfaces, don't scratch or gouge the machined aluminum surfaces.
  14.  
  15. Cover the engine block with a sheet of plastic or clean shop towels to keep any dirt and foreign objects out of the combustion chambers.
  16.  

To install:

Use new head bolts when installing the cylinder head. Do not apply oil to the head bolt threads.

  1. Make sure all mating surfaces are clean and free of oil, coolant, or gasket residue.
  2.  
  3. Install new cylinder head gaskets.
  4.  
  5. Install the cylinder head. Install the new head bolts and tighten them by hand only.
  6.  
  7. Follow these steps to tighten the cylinder head bolts to their final torque specification:
    1. Use a two-step crisscross pattern to tighten the 11mm bolts to 47 ft. lbs. (64 Nm). Start tightening with the center bolts, and work toward the outer bolts.
    2.  
    3. Tighten the 8mm bolts to 15 ft. lbs. (21 Nm). Start with the bolt closest to the exhaust side of the head and work toward the intake side.
    4.  

  8.  
  9. 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.
  10.  
  11. Tighten the valve cover bolts to 6 ft. lbs. (8 Nm) in crisscross pattern.
  12.  
  13. Verify that the camshaft and crankshaft timing marks are properly aligned.
  14.  
  15. Install and tension the timing belt. Tighten the pusher bolts to 14 ft. lbs. (19 Nm).
  16.  
  17. 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).
  18.  
  19. Install the upper timing belt covers and tighten the bolts to 13 ft. lbs. (18 Nm).
  20.  
  21. Fit the oil cooler line brackets onto the timing cover and tighten the bolts to 13 ft. lbs. (18 Nm).
  22.  
  23. Install the engine coolant manifold and reconnect the heater hoses. Tighten the bolts to 16 ft. lbs. (22 Nm).
  24.  
  25. Install the dipstick tube bracket.
  26.  
  27. Raise and safely support the vehicle. Install and reconnect the front exhaust pipes. Reconnect the oxygen sensors. Lower the vehicle.
  28.  
  29. Install the intake manifold with a new gasket. Tighten the bolts and nuts to 17 ft. lbs. (24 Nm).
  30.  
  31. Reconnect the fuel injector wiring harness. 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. Install the hood.
  56.  
  57. Verify that all fuel lines, vacuum and coolant hoses, and wiring harness have been reconnected.
  58.  
  59. Refill the engine with fresh coolant.
  60.  
  61. Drain the engine oil. Install a new oil filter and refill the engine with fresh oil. If the engine oil was severely contaminated with coolant, a second oil and filter change may be necessary.
  62.  
  63. 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.
  64.  
  65. Bleed any air from the cooling system.
  66.  
  67. Bleed the power steering system if necessary.
  68.  
  69. Warm the engine up to normal operating temperature and check the operation of the thermostat and water pump.
  70.  
  71. Check the throttle cable operation and adjustment.
  72.  
  73. Check the engine oil level and add if necessary.
  74.  

CLEANING AND INSPECTION



See Figures 32, 33, 34, 35 and 37



Click image to see an enlarged view

Fig. Fig. 32: Check the cylinder head for warpage



Click image to see an enlarged view

Fig. Fig. 33: A soft wire brush can be used to clean the valve seats. Take care not to damage the aluminum head



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Fig. Fig. 34: Use a gasket scraper to remove the bulk of the old head gasket from the mating surface



Click image to see an enlarged view

Fig. Fig. 35: An electric drill equipped with a wire wheel will expedite complete gasket removal



Click image to see an enlarged view

Fig. Fig. 36: Check the cylinder head for warpage along the center using a straightedge and a feeler gauge



Click image to see an enlarged view

Fig. Fig. 37: Be sure to check for warpage across the cylinder head at both diagonals

Chip carbon away from the valve heads, combustion chambers, and ports, using a chisel made of hardwood. Remove the remaining deposits with a stiff wire brush.

Be sure that the deposits are actually removed, rather than burnished.

Have the cylinder cleaned at a machine shop to remove grease, corrosion, and scale from the water passages. Clean the remaining cylinder head parts in an engine cleaning solvent. Do not remove the protective coating from the springs.


WARNING
Aluminum cylinder head cannot be hot-tanked in the same solution that is used for cast iron.

Place a straightedge across the gasket surface of the cylinder head. Using feeler gauges, determine the clearance at the center of the straightedge. If warpage exceeds 0.003 in. (0.08mm) in a 6 in. (152mm) span, or 0.006 in. (0.15mm) over the total length, the cylinder head must be resurfaced.

If warpage exceeds the manufacturer's maximum tolerance for material removal, the cylinder head must be replaced.

When milling the cylinder heads of V-type engines, the intake manifold mounting position is altered, and must be corrected by milling the manifold flange a proportionate amount.

If the valve or seats are damaged they can be replaced. It is recommend to have seats checked and replaced by a machine shop. Proper tools are required for exact fit of valves and valve seat inserts in aluminum heads.

RESURFACING



This procedure should be performed only by a machine shop.

Whenever the cylinder head is removed, check the flatness of the cylinder head gasket surface as follows:

  1. Make sure all dirt and old gasket material has been cleaned from the cylinder head. Any foreign material left on the head gasket surface can cause a false measurement.
  2.  
  3. Place a straightedge straight across and diagonally across the gasket surface of the cylinder head (in the positions shown in the figures). Using feeler gauges, determine the clearance at the center of the straightedge.
  4.  
  5. If warpage exceeds the 0.004 in. (0.10mm) then the cylinder head should likely be resurfaced or replaced. Contact a reputable machine shop for machining service and recommendations.
  6.  

When resurfacing the cylinder head(s), the intake manifold mounting position is altered and must be corrected by machining a proportionate amount from the intake manifold flange.

 
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