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

Timing Belt Front Cover

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REMOVAL & INSTALLATION



Diesel Engine
  1. 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(s). Remove the alternator and bracket.
  2.  
  3. Remove the radiator hoses and the radiator.
  4.  
  5. Label and disconnect the necessary vacuum hoses and electrical connectors.
  6.  
  7. Remove the crankshaft pulley.
  8.  
  9. Remove the timing belt cover-to-engine bolts and the cover.
  10.  

To install:
  1. Install the timing belt cover-to-engine bolts and the cover.
  2.  
  3. Install the crankshaft pulley.
  4.  
  5. Connect the necessary vacuum hoses and electrical connectors.
  6.  
  7. Install the radiator hoses and the radiator.
  8.  
  9. Install the cooling fan assembly and the drive belt(s). Install the alternator and bracket.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Refill the cooling system.
  14.  
  15. Start the engine, allow it to reach normal operating temperatures and check for leaks.
  16.  

2.3L and 2.6L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove all accessory drive belts.
  4.  
  5. Remove the cooling fan and pulley.
  6.  
  7. If equipped, remove the power steering pump from its mount and unbolt the hydraulic line from the upper timing cover. Move the pump and hydraulics lines out of the work area. If the lines must be disconnect, plug them to prevent fluid loss and contamination.
  8.  
  9. Remove the upper timing cover.
  10.  
  11. Rotate the crankshaft to set the engine at TDC/compression for the No. 1 cylinder. The arrow mark on the camshaft timing sprocket aligns with the mark on the back timing cover.
  12.  
  13. Use a suitable holder tool to remove the crankshaft pulley bolt.
  14.  

The starter motor can be removed and a bar-type crankshaft holder tool installed in its opening.

  1. Remove the crankshaft pulley.
  2.  
  3. Remove the lower timing belt cover.
  4.  

To install:
  1. Clean any oil, coolant, or excess sealant from the timing belt covers before installation.
  2.  
  3. Install the lower timing belt covers. Tighten the bolts to 4.4 ft. lbs. (6 Nm).
  4.  
  5. Install the crankshaft pulley and bolt. Tighten the bolt to 87 ft. lbs. (118 Nm).
  6.  
  7. Remove the crankshaft holder tool. Install the starter motor if it was removed and tighten its bolts to 30 ft. lbs. (40 Nm).
  8.  
  9. Install the upper timing belt cover.
  10.  
  11. If removed, install the power steering pump. Tighten the mounting bolts to 27 ft. lbs. (37 Nm). Reconnect the fluid line fittings with new washers and tighten the banjo bolt to 14 ft. lbs. (19 Nm).
  12.  
  13. Install the cooling fan and pulley and tighten the pulley mounting bolts to 20 ft. lbs. (26 Nm).
  14.  
  15. Install and adjust the accessory drive belts.
  16.  
  17. Verify that all wiring harnesses and vacuum lines have reconnected correctly.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Refill and bleed the power steering system.
  22.  

3.2L Engine
1992-95 VEHICLES

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the upper fan shroud from the radiator.
  8.  
  9. Remove the four nuts retaining the cooling fan assembly. Remove the cooling fan.
  10.  
  11. Loosen and remove the power steering drive belt.
  12.  
  13. Loosen and remove the air conditioning compressor drive belt.
  14.  
  15. Loosen and remove the alternator drive belt.
  16.  
  17. Remove the fan pulley assembly.
  18.  
  19. Remove the crankshaft pulley center bolt. Remove the crankshaft pulley.
  20.  
  21. Remove the two oil cooler hose bracket bolts on the timing cover. Remove the oil cooler hose.
  22.  
  23. Remove the timing belt cover.
  24.  

To install:
  1. Install the timing belt cover and tighten bolts to 12 ft. lbs. (17 Nm).
  2.  
  3. Install the oil cooler hose and tighten brackets to 16 ft. lbs. (22 Nm).
  4.  
  5. Install the crankshaft pulley. Use tool No. J-8614-01, or an equivalent pulley holder and tighten the bolts to 123 ft. lbs. (167 Nm).
  6.  
  7. Install fan pulley assembly and tighten the bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install and adjust the alternator drive belt.
  10.  
  11. Install and adjust the air conditioning compressor drive belt.
  12.  
  13. Install and adjust the power steering pump drive belt.
  14.  
  15. Install cooling fan assembly and tighten bolts to 69 inch lbs. (8 Nm).
  16.  
  17. Install upper fan shroud to the radiator.
  18.  
  19. Install air cleaner assembly.
  20.  
  21. Refill the engine with fresh coolant. Bleed the cooling system.
  22.  
  23. Connect the negative battery cable.
  24.  

1996 VEHICLES

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Timing belt front cover-3.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the air cleaner assembly and intake air duct.
  6.  
  7. Remove the upper fan shroud from the radiator.
  8.  
  9. Remove the four nuts retaining the cooling fan assembly. Remove the cooling fan.
  10.  
  11. Loosen and remove the power steering drive belt.
  12.  
  13. Loosen and remove the air conditioning compressor drive belt.
  14.  
  15. Loosen and remove the alternator drive belt.
  16.  
  17. Remove the fan pulley assembly.
  18.  
  19. Remove the two oil cooler hose bracket bolts on the timing cover. Move the oil cooler hose off of the lower timing cover.
  20.  
  21. Remove the upper timing belt covers.
  22.  
  23. 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.
  24.  
  25. Use tool No. J-8614-01, or a suitable pulley holding tool to remove the crankshaft pulley center bolt. Remove the crankshaft pulley.
  26.  
  27. Remove the lower timing belt cover.
  28.  

To install:
  1. Install the lower timing belt cover and tighten bolts to 12 ft. lbs. (17 Nm).
  2.  
  3. Install the crankshaft pulley. Use tool No. J-8614-01, or an equivalent pulley holder and tighten the bolts to 123 ft. lbs. (167 Nm).
  4.  
  5. Verify that the timing marks align and that the No. 2 piston is at TDC/compression.
  6.  
  7. Install the upper timing belt covers and tighten the bolts to 12 ft. lbs. (17 Nm).
  8.  
  9. Fit oil cooler hose onto the timing cover and tighten the bracket bolts to 16 ft. lbs. (22 Nm).
  10.  
  11. Install fan pulley assembly and tighten the bolts to 16 ft. lbs. (22 Nm).
  12.  
  13. Install and adjust the alternator drive belt.
  14.  
  15. Install and adjust the air conditioning compressor drive belt.
  16.  
  17. Install and adjust the power steering pump drive belt.
  18.  
  19. Install cooling fan assembly and tighten bolts to 6 ft. lbs. (8 Nm).
  20.  
  21. Install upper fan shroud to the radiator.
  22.  
  23. Install air cleaner assembly and intake air duct.
  24.  
  25. Refill the engine with fresh coolant. Bleed the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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