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

Rocker Arm Cover

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REMOVAL & INSTALLATION



4-Cylinder Gasoline Engines
EXCEPT 2.2L ENGINE

See Figure 1



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Fig. Fig. 1: Rocker arm cover removal on a single overhead camshaft 4-cylinder engine

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the air cleaner (carbureted) and air inlet hose (EFI).
  4.  
  5. Remove the PCV hose.
  6.  
  7. Label and remove the spark plug wires.
  8.  
  9. Remove the timing belt cover attaching bolts, if so equipped.
  10.  
  11. Disconnect the power brake booster hose and throttle cable if in the way.
  12.  
  13. Remove the rocker arm cover bolts and cover.
  14.  
  15. If the cover will not come loose, tap the sides with a rubber hammer to dislodge.
  16.  

To install:
  1. Clean the gasket mating surfaces with a scraper and solvent.
  2.  
  3. Install a new gasket and apply a 0.08-0.12 in. (2-3mm) bead of RTV sealer around the gasket surface.
  4.  
  5. Install the rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the spark plug wires, PCV hose, brake booster hose and throttle cable if removed.
  8.  
  9. Install the air cleaner or air inlet hose.
  10.  
  11. Connect the battery cable, start the engine and check for leaks.
  12.  

2.2L ENGINE
  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the and air inlet hose (EFI).
  4.  
  5. Remove the PCV hose. Remove the center cover.
  6.  
  7. Label and remove the spark plug wires if helpful.
  8.  
  9. Remove the brake booster vacuum hose.
  10.  
  11. Remove the rocker arm cover bolts and cover.
  12.  
  13. If the cover will not come loose, tap the sides with a rubber hammer to dislodge.
  14.  

To install:
  1. Clean the gasket mating surfaces with a scraper and solvent. Be careful not to damage aluminum surfaces.
  2.  
  3. Install a new gasket and apply a 0.08-0.12 in. (2-3mm) bead of RTV sealer around the gasket surface.
  4.  
  5. Install the rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the spark plug wires, brake vacuum hose and PCV hose.
  8.  
  9. Install the air cleaner or air inlet hose.
  10.  
  11. Connect the battery cable, start the engine and check for leaks.
  12.  

Diesel Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the PCV valve from the rocker arm cover and the PCV valve hose.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the rocker arm cover-to-cylinder head bolts and remove the cover from the engine.
  8.  

DO NOT pry on the cover to remove it. If it sticks, use your palm or a rubber mallet to bump it rearwards, from the front.

  1. Using a putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  
  3. To install, use a new gasket and reverse the removal procedures. Torque the rocker arm cover-to-cylinder head bolts to 9-13 ft. lbs. (12-18 Nm). Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  4.  

2.8L and 3.1L Engines

See Figures 2, 3 and 4



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Fig. Fig. 2: Rocker arm cover removal may involve removal of hoses, brackets and other components



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Fig. Fig. 3: Rocker arm cover removal on a V6, 2.8L engine shown



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Fig. Fig. 4: Removing the rocker arm cover-2.8L engine

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the ignition coil and bracket (RH) or the crankcase ventilation valve (LH).
  6.  
  7. Label and remove the spark plug wires from the bracket at the rocker arm cover stud.
  8.  
  9. Remove the PCV valve (RH).
  10.  
  11. Remove the throttle cable and alternator (RH only).
  12.  
  13. Remove the rocker arm cover nuts, reinforcements, cover and gasket. If the cover sticks to the head, bump the end of the cover with a rubber hammer. Do NOT damage the sealing flange.
  14.  

To install:
  1. Clean the gasket mating surfaces with a scraper and solvent.
  2.  
  3. Install the rocker arm cover with a new gasket. Apply RTV sealer to the cylinder head-to-intake manifold contact points.
  4.  
  5. Install the rocker arm cover nuts and reinforcements. Torque the cover bolts to 72 inch lbs. (8 Nm).
  6.  
  7. Install the throttle cable and alternator (RH only).
  8.  
  9. Install the PCV valve (RH).
  10.  
  11. Install the spark plug wires to the bracket at the rocker arm cover stud.
  12.  
  13. Install the ignition coil and bracket (RH) or the crankcase ventilation valve (LH).
  14.  
  15. Install the air cleaner.
  16.  
  17. Connect the negative (-) battery cable, start the engine and check for leaks.
  18.  

3.2L Engine

See Figures 5 and 6



Click image to see an enlarged view

Fig. Fig. 5: Removing the left-hand rocker arm cover on a 3.2L engine



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Fig. Fig. 6: Removing the right-hand rocker arm cover on a 3.2L engine

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the EGR pipe.
  6.  
  7. Remove the (PCV) crankcase ventilation valve (LH).
  8.  
  9. Label and remove the spark plug wires from the bracket at the rocker arm cover stud.
  10.  
  11. Remove the camshaft angle sensor (LH) or fuel hose (RH).
  12.  
  13. Remove the throttle cable (LH) or heater pipe (RH).
  14.  
  15. Remove the rocker arm cover nuts, reinforcements, cover and gasket. If the cover sticks to the head, bump the end of the cover with a rubber hammer. Do NOT damage the sealing flange.
  16.  

To install:
  1. Clean the gasket mating surfaces with a scraper and solvent.
  2.  
  3. Install the rocker arm cover with a new gasket. Apply RTV sealer to the cylinder head-to-intake manifold contact points.
  4.  
  5. Install the rocker arm cover nuts and reinforcements. Torque the cover bolts to 72 inch lbs. (8 Nm).
  6.  
  7. Install the throttle cable. Torque the body and cable bolts to 14 ft.lbs. (19 Nm).
  8.  
  9. Install the PCV valve.
  10.  
  11. Install the EGR pipe; torque the manifold side to 20 ft. lbs. (28 Nm) and the head cover side to 4.5 ft. lbs. (6 Nm).
  12.  
  13. Install the spark plug wires to the bracket at the rocker arm cover stud.
  14.  
  15. Install the ignition coil and bracket and crankcase ventilation valve.
  16.  
  17. Install the air cleaner.
  18.  
  19. Connect the negative (-) battery cable, start the engine and check for leaks.
  20.  

 
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