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

Timing Belt

Print

REMOVAL & INSTALLATION



Diesel Engine

See Figures 1, 2, 3 and 4



Click image to see an enlarged view

Fig. Fig. 1: Injection pump and camshaft alignment marks-diesel engine



Click image to see an enlarged view

Fig. Fig. 2: Removing the timing belt holder-diesel engine



Click image to see an enlarged view

Fig. Fig. 3: Injection pump alignment marks-diesel engine



Click image to see an enlarged view

Fig. Fig. 4: Tensioner pulley bolt sequence-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 timing belt cover. Remove the injection pump sprocket flange.
  2.  
  3. Using a prybar, remove the tension spring from the timing belt tensioner.
  4.  

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

  1. Remove the tensioner pulley bolt and the pulley.
  2.  
  3. Remove the timing belt and discard it.
  4.  

To install:
  1. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.
  2.  
  3. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.
  4.  
  5. Using a new timing belt, install it in the following sequence: crankshaft sprocket, camshaft sprocket and the injection pump sprocket; the slack must be between the injection pump and camshaft sprockets.
  6.  
  7. Install the tension center and the tension pulley so the end of the tension center is fitted against both pins on the timing pulley housing.
  8.  
  9. Hand tighten the nut so the tension pulley can be rotated freely.
  10.  
  11. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (30-48 Nm).
  12.  
  13. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.
  14.  
  15. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-128 Nm).
  16.  
  17. Install the injection pump sprocket flange; the hole in the outer circumference of the flange should be aligned with the triangular timing mark on the injection pump sprocket.
  18.  
  19. Rotate the crankshaft 2 full turns clockwise to bring the No. 1 piston to TDC of the compression stroke. Make sure the triangular timing mark on the timing sprocket is aligned with the hole in the flange, then, measure the timing belt tension; it should be 33-55 lbs.
  20.  
  21. Install the timing belt cover.
  22.  
  23. Connect the negative battery cable.
  24.  

1986-92 2.3L and 2.6L Engines

See Figures 5, 6, 7, 8 and 9



Click image to see an enlarged view

Fig. Fig. 5: Crankshaft sprocket timing mark-2.3L and 2.6L engine



Click image to see an enlarged view

Fig. Fig. 6: Camshaft sprocket timing mark-2.3L and 2.6L engine



Click image to see an enlarged view

Fig. Fig. 7: Timing belt installation sequence-2.3L and 2.6L engines



Click image to see an enlarged view

Fig. Fig. 8: Timing belt tensioner lockbolt-2.3L and 2.6L engines



Click image to see an enlarged view

Fig. Fig. 9: Timing belt and tensioner assembly-2.3L and 2.6L engine

  1. Disconnect the negative battery cable. Remove the crankshaft pulley.
  2.  
  3. Remove the upper and lower timing belt covers.
  4.  
  5. Rotate the crankshaft to align the camshaft sprocket with the mark on the rear timing cover and the crankshaft sprocket keyway with the mark on the oil seal retainer cover.
  6.  

With the timing marks aligned, the engine is positioned on the TDC of the No. 4 cylinder's compression stroke.

  1. Loosen the timing belt tensioner and relax the tension and remove the timing belt from the crankshaft sprocket.
  2.  

To install:
  1. With the crankshaft and the camshaft sprockets aligned with the timing marks, install the timing belt. Install the timing belt using the following sequence: the crankshaft sprocket, the oil pump sprocket and the camshaft sprocket.
  2.  
  3. Apply the tensioner pulley spring pressure to the timing belt.
  4.  
  5. Rotate the crankshaft 2 complete revolutions in the opposite direction of rotation and realign the timing marks.
  6.  
  7. Loosen the tensioner pulley bolt to allow the spring to adjust the correct tension. Torque the tensioner pulley bolt to 14 ft. lbs. (20 Nm).
  8.  
  9. Install the timing covers and the crankshaft pulley.
  10.  
  11. Connect the negative battery cable. Start the engine and check for leaks.
  12.  

1993-96 2.3L and 2.6L Engines

See Figures 5, 6, 7, 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen and remove the engine accessory drive belts.
  4.  
  5. Remove the cooling fan assembly and the water pump pulley.
  6.  
  7. Drain the fluid from the power steering reservoir.
  8.  
  9. Unbolt and remove the power steering pump. Unbolt the hydraulic line brackets from the upper timing cover and move the pump out of the work area without disconnecting the hydraulic lines.
  10.  
  11. Disconnect and remove the starter motor if a flywheel holder (part No. J-38674) is to be used.
  12.  
  13. Remove the upper timing belt cover.
  14.  
  15. Rotate the crankshaft to set the engine at TDC/compression for the No. 1 cylinder. The arrow mark on camshaft sprocket aligns with mark on the rear timing cover.
  16.  
  17. Remove the crankshaft pulley.
  18.  
  19. Remove the lower timing belt cover.
  20.  
  21. Verify that the engine is set at TDC/compression for the No. 1 cylinder. The notch on the crankshaft sprocket aligns with the pointer on the oil seal retainer.
  22.  
  23. Release and remove the tensioner spring to release the timing belt's tension.
  24.  
  25. Remove the timing belt.
  26.  
  27. Unbolt the tensioner pulley bracket from the engine's front cover.
  28.  
  29. If necessary, unbolt and remove the camshaft sprockets. Use a puller to remove the crankshaft pulley if necessary. Don't loose the crankshaft sprocket key.
  30.  

To install:
  1. Install the camshaft and crankshaft sprockets if they were removed. Align the timing marks and be sure to install any keys. Tighten the camshaft sprocket bolt to 43 ft. lbs. (59 Nm).
  2.  
  3. Install the tensioner assembly. Tighten the tensioner mounting bolt to 14 ft. lbs. (19 Nm). Tighten the cap bolt to 9 ft. lbs. (13 Nm).
  4.  
  5. Make sure the crankshaft and the camshaft sprockets are aligned with their timing marks. Install the timing belt onto the sprockets using the following sequence: first, crankshaft sprocket; second, oil pump sprocket; third, camshaft sprocket.
  6.  
  7. Loosen the tensioner mounting bolt. This will allow the tensioner spring to apply pressure to the timing belt.
  8.  
  9. After the spring has pulled the timing belt as far as possible, temporarily tighten the tensioner mounting bolt to 14 ft. lbs. (19 Nm).
  10.  

Remove the flywheel holder before rotating the crankshaft. Reinstall the holder to torque the crankshaft pulley bolt.

  1. Rotate the crankshaft counterclockwise two complete revolutions to check the rotation of the belt and the alignment of the timing marks. Listen for any rubbing noises which may mean the belt is binding.
  2.  
  3. Loosen the tensioner pulley bolt to allow the spring to adjust the correct tension. Then, retighten the tensioner pulley bolt to 14 ft. lbs (19 Nm).
  4.  
  5. Install the lower timing cover and the crankshaft pulley.
  6.  
  7. Tighten the crankshaft pulley bolt to 87 ft. lbs. (118 Nm). Tighten the small pulley bolts to 6 ft. lbs. (8 Nm).
  8.  
  9. Install the upper timing cover.
  10.  
  11. Install the starter if it was removed. Tighten the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Install the power steering pump. If the hydraulic lines were disconnected, refill and bleed the power steering system.
  14.  
  15. Install the water pump pulley and tighten its nut to 20 ft. lbs. (26 Nm).
  16.  
  17. Install the cooling fan assembly.
  18.  
  19. Install and adjust the accessory drive belts.
  20.  
  21. Connect the negative battery cable.
  22.  

1992-95 3.2L Engine

See Figures 10, 11, 12, 13 and 14



Click image to see an enlarged view

Fig. Fig. 10: Crankshaft sprocket groove and alignment marks-3.2L engine



Click image to see an enlarged view

Fig. Fig. 11: Camshaft sprocket alignment marks-3.2L engine



Click image to see an enlarged view

Fig. Fig. 12: Timing belt direction of installation and rotation-3.2L engine



Click image to see an enlarged view

Fig. Fig. 13: Timing belt tensioner pulley with pusher installed-3.2L engine



Click image to see an enlarged view

Fig. Fig. 14: Large paper clips are an excellent way to hold the belt in place during service. Timing belt tensioner pulley with pusher installed-3.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant into a sealable container.
  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. Remove the power steering drive belt.
  12.  
  13. Remove the air conditioning compressor drive belt.
  14.  
  15. Remove the alternator drive belt.
  16.  
  17. Remove the fan pulley assembly.
  18.  
  19. Set the timing belt so that the timing marks on the sprockets align with those on the oil pump and front plate.
  20.  
  21. Remove the crankshaft pulley center bolt. Remove the crankshaft pulley.
  22.  
  23. Remove the two oil cooler hose bracket fixing bolts on the timing cover. Remove the oil cooler hoses and bracket.
  24.  
  25. Remove the timing belt cover.
  26.  


WARNING
Set the timing sprockets so that the crankshaft and camshaft sprocket timing marks align with the timing marks on the oil pump and front plate. When the timing marks are align, no pistons are at TDC for the compression stroke. Valve damage may result if the sprockets and belt are out of alignment.

  1. Remove the pusher. The rod must always be facing upward.
  2.  
  3. Mark the timing belt, cam pulley and crankshaft pulley. Remove the timing belt.
  4.  

To install:
  1. Align the groove on the crankshaft timing pulley with mark on the oil pump.
  2.  
  3. Align the marks on the camshaft timing pulleys with the dots on the front plate.
  4.  
  5. Install the timing belt. Align the dotted marks on the timing belt with the mark on the crankshaft pulley.
  6.  
  7. Align the white line on the timing belt with the alignment mark on the right bank camshaft timing pulley. Secure the belt with a small clamp.
  8.  
  9. Turn the crankshaft counterclockwise to remove the slack between the crankshaft pulley and the right camshaft timing pulley.
  10.  
  11. Install the belt on the water pump pulley.
  12.  
  13. Install the belt on the idler pulley.
  14.  
  15. Align the white alignment mark on the timing belt with the alignment mark on the left bank camshaft timing pulley.
  16.  
  17. Install the crankshaft pulley and tighten the center bolt by hand. Turn the crankshaft pulley clockwise to give slack between the crankshaft timing pulley and the right bank camshaft timing pulley.
  18.  
  19. Install the pusher while pushing the tension pulley to the belt.
  20.  
  21. Pull the pin out from the pusher.
  22.  
  23. Remove the clamps from the pulleys. Turn the crankshaft pulley clockwise two turns. Measure the rod protrusion to be sure it is between 0.16-0.24 in. (4-6mm).
  24.  
  25. Check the stick-out of the pusher plunger against the belt tensioner. Clearance should be 0.16-0.24 in. (4-6mm).
  26.  
  27. Tighten adjusting bolt to 31 ft. lbs. (42 Nm).
  28.  
  29. Tighten pusher bolt to 14 ft. lbs. (19 Nm).
  30.  
  31. Remove crankshaft pulley. Install the timing belt cover and tighten bolts to 12 ft. lbs. (17 Nm).
  32.  
  33. Install the oil cooler hose and tighten brackets to 16 ft. lbs. (22 Nm).
  34.  
  35. Install the crankshaft pulley and tighten bolts to 123 ft. lbs. (167 Nm).
  36.  
  37. Install fan pulley assembly and tighten fixing bolts to 16 ft. lbs. (22 Nm).
  38.  
  39. Install and adjust alternator drive belt.
  40.  
  41. Install and adjust air conditioning drive belt.
  42.  
  43. Install and adjust power steering pump drive belt.
  44.  
  45. Install cooling fan assembly and tighten bolts to 69 inch lbs. (8 Nm).
  46.  
  47. Install upper fan shroud to the radiator.
  48.  
  49. Install air cleaner assembly.
  50.  
  51. Refill and bleed the cooling system.
  52.  
  53. Reconnect the negative battery cable.
  54.  
  55. Check the operation of the engine and valve train.
  56.  

ADJUSTMENT

WARNING
It is very highly recommended that a timing belt be replaced any time its tension is released.

A timing belt should not be viewed as an adjustable component. The timing belt's tension cannot be increased to compensate for wear. If the engine has been disassembled for mechanical work, a new timing belt should be installed. The small cost of a new timing belt is cheap insurance against expensive engine damage which can be caused by the failure of a re-used timing belt.

SETTING THE TENSION OF A NEW TIMING BELT
  1. Verify that the camshaft sprocket timing marks are aligned. The groove and the keyway on the crankshaft timing sprocket align with mark on the oil pump. The white pointers on the camshaft timing sprockets align with the dots on the front plate.
  2.  
  3. Install the timing belt. Use clips to secure the belt onto each sprocket until the installation is complete. Align the dotted marks on the timing belt with the timing mark opposite the groove on the crankshaft sprocket.
  4.  

The arrows on the timing belt must follow the belt's direction rotation. The manufacturer's trademark on the belt's spine should be readable left-to-right when the belt is installed.

  1. Align the white line on the timing belt with the alignment mark on the right bank camshaft timing pulley. Secure the belt with a clip.
  2.  
  3. Rotate the crankshaft counterclockwise to remove the slack between the crankshaft sprocket and the right camshaft timing sprocket.
  4.  
  5. Install the belt around the water pump pulley.
  6.  
  7. Install the belt on the idler pulley.
  8.  
  9. Align the white alignment mark on the timing belt with the alignment mark on the left bank camshaft timing sprocket.
  10.  
  11. Install the crankshaft pulley and tighten the center bolt by hand. Rotate the crankshaft pulley clockwise to give slack between the crankshaft timing pulley and the right bank camshaft timing pulley.
  12.  
  13. Insert a 1.4mm piece of wire through the hole in the pusher to hold the rod in. Install the pusher assembly while pushing the tension pulley toward the belt.
  14.  
  15. Pull the pin out from the pusher to release the rod.
  16.  
  17. Remove the clamps from the sprockets. Rotate the crankshaft pulley clockwise two turns. Measure the rod protrusion to be sure it is 0.16-0.24 in. (4-6mm).
  18.  
  19. If the tensioner pulley bracket pivot bolt was removed, tighten it to 31 ft. lbs. (42 Nm).
  20.  
  21. Tighten pusher bolts to 14 ft. lbs. (19 Nm).
  22.  
  23. Remove crankshaft pulley. Install the lower and upper timing belt covers and tighten their bolts to 12 ft. lbs. (17 Nm).
  24.  
  25. Install the crankshaft pulley and tighten the pulley bolt to 123 ft. lbs. (167 Nm).
  26.  

TIMING BELT INSPECTION
  1. Disconnect the negative and positive battery cables.
  2.  
  3. Label and disconnect the ignition wires and remove the spark plugs. Remove the upper timing belt cover.
  4.  
  5. Rotate the crankshaft to align the camshaft timing marks with the pointer dots on the back covers. Verify that the pointer on the crankshaft aligns with the mark on the lower timing cover.
  6.  

When the timing marks are aligned on 1994-95 vehicles, no pistons will be at TDC/compression. When the timing marks are aligned on 19951/2-96 vehicles, the No. 2 piston is at TDC/compression.

  1. Rotate the crankshaft pulley to cycle the belt through its entire rotation.
  2.  
  3. Inspect the entire length of the timing belt. Look carefully for any signs of the following conditions:
    1. Cracked, chipped, or broken teeth.
    2.  
    3. Fraying, separation, or heat damage to the belt's rubber and fiber layers.
    4.  
    5. Oil or coolant leaks which may have contaminated the belt.
    6.  
    7. Make sure the timing marks align. Misaligned marks may indicate that the belt has jumped one or more teeth, or has been improperly tensioned.
    8.  

  4.  
  5. Check the camshaft and crankshaft oil seals for any signs of leakage. Also check the water pump for leakage. The source of any oil or coolant leaks must be found and corrected before a new timing belt is installed.
  6.  
  7. Replace the timing belt if it's damaged in any way, or if its condition or the vehicle's maintenance history is uncertain. Isuzu's recommended service interval for timing belt replacement is 60,000 miles (96,000 Km). It's also recommended to install a new water pump when the timing belt is replaced.
  8.  
  9. After inspection, retighten the crankshaft pulley bolt to 123 ft. lbs. (167 Nm). Install the timing belt covers and valve covers. Install the spark plugs and reconnect the ignition wires. Reconnect the battery cables.
  10.  

1996 3.2L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant into a sealable container.
  4.  
  5. Remove the air cleaner assembly and intake air duct.
  6.  
  7. Disconnect the upper radiator hose from the coolant inlet.
  8.  
  9. Remove the upper fan shroud from the radiator.
  10.  
  11. Remove the four nuts retaining the cooling fan assembly. Remove the cooling fan from the fan pulley.
  12.  
  13. Loosen and remove the power steering drive belt.
  14.  
  15. Loosen and remove the air conditioning compressor drive belt.
  16.  
  17. Loosen and remove the alternator drive belt.
  18.  
  19. Remove the upper timing belt covers.
  20.  
  21. Remove the fan pulley assembly.
  22.  
  23. Rotate the crankshaft to align the camshaft timing marks with the pointer dots on the back covers. Verify that the pointer on the crankshaft aligns with the mark on the lower timing cover.
  24.  

When the timing marks are aligned on 1994-95 vehicles, no pistons will be at TDC/compression. When the timing marks are aligned on 19951/2-96 vehicles, the No. 2 piston is at TDC/compression.


WARNING
Align the camshaft and crankshaft sprockets with their alignment marks before removing the timing belt. Failure to align the belt and sprocket marks may result in valve damage.

  1. Use tool No. J-8614-01, or a suitable pulley holding tool to remove the crankshaft pulley center bolt. Remove the crankshaft pulley.
  2.  
  3. Disconnect the two oil cooler hose bracket bolts on the timing cover. Move the oil cooler hoses and bracket off of the lower timing cover.
  4.  
  5. Remove the lower timing belt cover.
  6.  
  7. Remove the pusher assembly (tensioner) from below the 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.
  8.  
  9. Remove the timing belt.
  10.  
  11. Use tool No. J-41472, or a suitable pulley holding tool to loosen and remove the camshaft sprocket bolt. Remove the camshaft sprockets.
  12.  
  13. Inspect the water pump and replace it if there is any doubt about its condition.
  14.  
  15. Repair any oil or coolant leaks before installing a new timing belt. If the timing belt has been contaminated with oil or coolant, or is damaged, it must be replaced.
  16.  

To install:
  1. Install the camshaft sprockets. Use a holding tool, and tighten their bolts to 41 ft. lbs. (55 Nm).
  2.  
  3. Verify that the sprocket timing marks are still aligned. The groove and the keyway on the crankshaft timing sprocket align with mark on the oil pump. The white pointers on the camshaft timing sprockets align with the dots on the front plate.
  4.  
  5. Install the timing belt. Use clips to secure the belt onto each sprocket until the installation is complete. Align the dotted marks on the timing belt with the timing mark opposite the groove on the crankshaft sprocket.
  6.  

The arrows on the timing belt must follow the belt's direction rotation. The manufacturer's trademark on the belt's spine should be readable left-to-right when the belt is installed.

  1. Align the white line on the timing belt with the alignment mark on the right bank camshaft timing pulley. Secure the belt with a clip.
  2.  
  3. Rotate the crankshaft counterclockwise to remove the slack between the crankshaft sprocket and the right camshaft timing sprocket.
  4.  
  5. Install the belt around the water pump pulley.
  6.  
  7. Install the belt on the idler pulley.
  8.  
  9. Align the white alignment mark on the timing belt with the alignment mark on the left bank camshaft timing sprocket.
  10.  
  11. Install the crankshaft pulley and tighten the center bolt by hand. Rotate the crankshaft pulley clockwise to give slack between the crankshaft timing pulley and the right bank camshaft timing pulley.
  12.  
  13. Insert a 1.4mm piece of wire through the hole in the pusher to hold the rod in. Install the pusher assembly while pushing the tension pulley toward the belt.
  14.  
  15. Pull the pin out from the pusher to release the rod.
  16.  
  17. Remove the clamps from the sprockets. Rotate the crankshaft pulley clockwise two turns. Measure the rod protrusion to be sure it is between 0.16-0.24 in. (4-6mm).
  18.  
  19. If the tensioner pulley bracket pivot bolt was removed, tighten it to 31 ft. lbs. (42 Nm).
  20.  
  21. Tighten pusher bolts to 14 ft. lbs. (19 Nm).
  22.  
  23. Remove the crankshaft pulley. Install the lower and upper timing belt covers and tighten their bolts to 12 ft. lbs. (17 Nm).
  24.  
  25. Fit the oil cooler hose onto the timing cover and tighten its mounting bracket bolts to 16 ft. lbs. (22 Nm).
  26.  
  27. Install the crankshaft pulley and tighten the pulley bolt to 123 ft. lbs. (167 Nm).
  28.  
  29. Install fan pulley assembly and tighten bolts to 16 ft. lbs. (22 Nm).
  30.  
  31. Install and adjust the alternator drive belt.
  32.  
  33. Install and adjust the air conditioning drive belt.
  34.  
  35. Install and adjust the power steering pump drive belt.
  36.  
  37. Install cooling fan assembly and tighten bolts to 6 ft. lbs. (8 Nm).
  38.  
  39. Install upper fan shroud.
  40.  
  41. Install air cleaner assembly and intake air duct.
  42.  
  43. Connect the upper radiator hose to the coolant inlet.
  44.  
  45. Refill and bleed the cooling system.
  46.  
  47. Connect the negative battery cable.
  48.  

 
label.common.footer.alt.autozoneLogo