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

Timing Sprockets

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REMOVAL & INSTALLATION



1.8L and 2.0L Engines

See Figures 1, 2 and 3



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Fig. Fig. 1: Keep the camshaft from turning using a prybar when removing or installing the camshaft sprocket



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Fig. Fig. 2: Tighten the camshaft bolt to the 55 ft. lbs. (75Nm)-1.8L and 2.0L engines



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Fig. Fig. 3: Using a puller to remove the crankshaft timing gear

CAMSHAFT SPROCKET
  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the rocker arm cover as outlined in this section.
  4.  
  5. Remove the rubber half plug in front of the camshaft sprocket.
  6.  
  7. Using a suitable prybar, insert it through one of the sprocket holes and remove the retaining bolt.
  8.  
  9. Release the timing chain tensioner as outlined in the Timing Chain portion of this section.
  10.  
  11. Wiggle the sprocket off of the camshaft. Use a small rubber hammer for assistance in removal if necessary.
  12.  
  13. Use a piece of wire to keep the timing chain from falling into the engine.
  14.  

To install:
  1. Install the sprocket with the timing marks aligned as shown in the Timing Chain portion of this section. Install the bolt and washer, torque the bolt to 55 ft. lbs. (75 Nm).
  2.  
  3. Install the rocker arm cover, connect the battery cable and, start the engine and check for leaks.
  4.  

CRANKSHAFT SPROCKET
  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the timing cover as outlined in this section.
  4.  
  5. Using a gear puller, remove the oil pump drive and crankshaft sprocket.
  6.  

To install:
  1. Install the crankshaft sprocket and oil pump drive using a suitable driver. Be careful not to damage the crankshaft. Install the timing chain and align the timing marks as illustrated in the Timing Chain portion of this section.
  2.  
  3. Install the timing cover and connect the negative battery cable.
  4.  
  5. Start the engine and check for leaks.
  6.  

2.3L and 2.6L Engines
CAMSHAFT SPROCKET

See Figure 4



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Fig. Fig. 4: Keep the camshaft from turning using a prybar when removing or installing the camshaft sprocket

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt.
  4.  
  5. Remove the camshaft sprocket-to-camshaft bolt and the sprocket.
  6.  

It may be necessary to use a mallet to tap the sprocket from the camshaft.

  1. Remove and replace the camshaft oil seal.
  2.  

To install:
  1. Align the camshaft sprocket-to-rear plate timing marks. With the crankshaft sprocket aligned with the timing mark, install the timing belt.
  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. (19 Nm).
  8.  
  9. Install the timing covers and the crankshaft pulley.
  10.  
  11. Connect the battery cable, start the engine and check for leaks.
  12.  

CRANKSHAFT SPROCKET
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt.
  4.  
  5. Remove the crankshaft sprocket-to-crankshaft bolt. Using a puller, pull the sprocket from the crankshaft.
  6.  
  7. Remove and replace the crankshaft oil seal.
  8.  

To install:
  1. Align the crankshaft sprocket-to-oil seal retainer plate timing marks.
  2.  
  3. With the camshaft sprocket aligned with its timing mark, install the timing belt.
  4.  
  5. Apply the tensioner pulley spring pressure to the timing belt.
  6.  
  7. Rotate the crankshaft 2 complete revolutions in the opposite direction of rotation and realign the timing marks.
  8.  
  9. Loosen the tensioner pulley bolt to allow the spring to adjust the correct tension. Torque the tensioner pulley bolt to 14 ft. lbs. (22 Nm).
  10.  
  11. Install the timing covers and the crankshaft pulley.
  12.  
  13. To complete the installation, reverse the removal procedures.
  14.  

Diesel Engine

See Figures 5, 6 and 7



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Fig. Fig. 5: Injection pump sprocket-diesel engine



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Fig. Fig. 6: Camshaft sprocket-diesel engine



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Fig. Fig. 7: Crankshaft sprocket-diesel engine

INJECTION PUMP SPROCKET
  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.  
  5. Using a 6mm, 1.25 pitch bolt, install the threaded portion into the threaded hole in the timing sprocket housing through the hole in the sprocket to prevent the sprocket from turning.
  6.  
  7. Remove the injection pump sprocket-to-shaft bolts.
  8.  
  9. Using a wheel puller, connect it to the injection pump sprocket and press it from the shaft.
  10.  

To install:
  1. Install the injection pump sprocket by aligning it with the key groove and torque the bolt to 42-52 ft. lbs. (56-70 Nm)
  2.  
  3. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.
  4.  
  5. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Hand tighten the nut so the tension pulley can be rotated freely.
  12.  
  13. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (30-48 Nm).
  14.  
  15. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.
  16.  
  17. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-130 Nm).
  18.  
  19. 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.
  20.  
  21. 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.
  22.  
  23. Install the timing belt cover.
  24.  
  25. To complete the installation, reverse the removal procedures.
  26.  
  27. Connect the negative battery cable. Refill the cooling system.
  28.  

CAMSHAFT SPROCKET
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover. Remove the injection pump sprocket flange.
  4.  
  5. Using a prybar, remove the tension spring from the timing belt tensioner.
  6.  

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

  1. Remove the tensioner pulley bolt and the pulley.
  2.  
  3. Remove the timing belt and discard it.
  4.  
  5. Using a 6mm, 1.25 pitch bolt, install the threaded portion into the threaded hole in the camshaft sprocket housing through the hole in the sprocket to prevent the sprocket from turning.
  6.  
  7. Using a wheel puller, connect it to the camshaft sprocket and press it from the camshaft.
  8.  

To install:
  1. Install the camshaft sprocket and torque the camshaft sprocket-to-camshaft bolt to 72-87 ft. lbs. (96-115 Nm).
  2.  
  3. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.
  4.  
  5. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Hand tighten the nut so the tension pulley can be rotated freely.
  12.  
  13. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (29-48 Nm).
  14.  
  15. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.
  16.  
  17. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-130 Nm).
  18.  
  19. 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.
  20.  
  21. 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.
  22.  
  23. Install the timing belt cover.
  24.  
  25. To complete the installation, reverse the removal procedures.
  26.  
  27. Connect the negative battery cable. Refill the cooling system.
  28.  

CRANKSHAFT SPROCKET
  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.
  2.  
  3. Using a prybar, remove the tension spring from the timing belt tensioner.
  4.  

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

  1. Remove the tensioner pulley bolt and the pulley.
  2.  
  3. Remove the timing belt and discard it.
  4.  
  5. Remove the crankshaft sprocket bolt.
  6.  

To remove the crankshaft sprocket bolt, it may be necessary to remove the starter or the flywheel cover plate to lock the flywheel; otherwise, it may be difficult to keep the crankshaft from turning.

  1. Using a puller tool press the crankshaft center and timing sprocket from the crankshaft.
  2.  

To install:
  1. Install the crankshaft center and timing sprocket to the crankshaft and install the bolt.
  2.  
  3. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.
  4.  
  5. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Hand-tighten the nut so the tension pulley can be rotated freely.
  12.  
  13. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (28-48 Nm).
  14.  
  15. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.
  16.  
  17. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-130 Nm).
  18.  
  19. 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.
  20.  
  21. 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.
  22.  
  23. Install the timing belt cover.
  24.  
  25. To complete the installation, reverse the removal procedures.
  26.  
  27. Connect the negative battery cable. Refill the cooling system.
  28.  

2.2L, 2.8L and 3.1L Engines

To service the timing gears and chain on these chain driven camshaft-equipped engines, refer to Timing Chain and Gears portion of this section. The camshaft sprocket and timing chain should always be replaced together. The crankshaft drive gear should be inspected. Even slight wear or damage on a gear will cause the chain to wear prematurely. It is usually best to replace all the gears and chain as a matched set.

3.2L Engine

Replacing the timing sprockets on the 3.2L engine is an involved process. For detailed steps to remove the front cover and timing belt, refer to Timing Belt portion of this section. Even slight wear on a sprocket can damage the timing belt. It is always recommended to install a new timing belt whenever the old belt is removed or timing sprockets are serviced.

 
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