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    Isuzu Cars and Trucks 1981-1991

    Timing Belt and Tensioner

    Print

    ADJUSTMENT
    Gasoline Engine
    1. Disconnect the negative battery cable. Remove the crankshaft pulley.
    2.  
    3. Remove the upper and lower timing belt covers.
    4.  
    5. Loosen the timing belt tensioner and relax the belt tension.
    6.  
    7. Apply the tensioner pulley spring pressure to the timing belt.
    8.  
    9. Rotate the crankshaft 2 complete revolutions in the opposite direction of rotation and realign the timing marks.
    10.  
    11. 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).
    12.  
    13. Install the timing covers and the crankshaft pulley.
    14.  



    Click image to see an enlarged view

    Fig. Timing belt alignment. Note the camshaft sprocket dowel pin and crankshaft woodruff key at the 12 o'clock position 4ZC1-U and 4XC1-T engines



    Click image to see an enlarged view

    Fig. Timing belt positioning all engines

    Diesel Engines
    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 the 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 and temporarily install the crankshaft pulley.
    2.  
    3. Rotate the crankshaft until the No. 1 cylinder is at the TDC of its compression stroke; make sure the alignment mark on the crankshaft pulley is aligned with timing indicator. Make sure the timing marks on the camshaft sprocket and the injection pump sprocket are facing each other at their closest point.
    4.  


    NOTE
    Any timing belt slack will be absorbed between the injection pump sprocket and camshaft sprocket.

    1. Adjust the timing belt tensioner pulley so the end of the tension center is fitted against the 2 pins on the timing pulley housing; hand tighten the nut, so the tension pulley can be rotated freely.
    2.  
    3. Make sure the tension spring is installed correctly. Torque the tension pulley nut to 22 and 1936 ft. lbs. (29 and 1947 Nm).
    4.  
    5. Rotate the crankshaft 2 complete revolutions in the clockwise direction. Further, turn the crankshaft 90and#x00B0; beyond TDC to settle the injection pump.
    6.  
    7. Loosen the tension pulley nut to allow the timing belt slackness to be taken up, then, tighten the tension pulley nut to 79 and 1994 ft. lbs. (108 and 19135 Nm).
    8.  


    NOTE
    Never attempt to rotate the crankshaft counterclockwise.

    1. Using a belt tension gauge, measure the belt tension between the injection pump sprocket and the crankshaft sprocket; it should be 33 and 1955 lbs. (45 and 1975 Nm).
    2.  

    REMOVAL AND INSTALLATION
    1985 and 1987 4XC1-U and 4XC1-T Engines
    1. Remove the engine by referring to the Engine Removal and Installation procedure in this section. Mount the engine to an engine stand.
    2.  
    3. Remove the accessory drive belts.
    4.  
    5. Remove the engine mounting bracket from the timing cover.
    6.  
    7. Rotate the crankshaft until the notch on the crankshaft pulley aligns with the 0 mark on the timing cover and the No. 4 cylinder is on TDC of the compression stroke.
    8.  
    9. Remove the starter and install the flywheel holding tool (J35271).
    10.  
    11. Remove the crankshaft bolt, boss and pulley.
    12.  
    13. Remove the timing cover bolts and the timing cover.
    14.  
    15. Loosen the tension pulley bolt.
    16.  
    17. Insert an Allen wrench into the tension pulley hexagonal hole and loosen the timing belt by turning the tension pulley clockwise.
    18.  
    19. Remove the timing belt.
    20.  


    NOTE
    Inspect the timing belt for signs of cracking, abnormal wear and hardening. Never expose the belt to oil, sunlight or heat. Avoid excessive bending, twisting or stretching.



    Click image to see an enlarged view

    Fig. Camshaft and crankshaft timing belt alignment marks 4XC1-U and 4XC1-T engines

    To install:

    1. Position the woodruff key on the crankshaft followed by the crankshaft timing gear. Align the groove on the timing gear with the mark on the oil pump.
    2.  
    3. Align the timing gear mark with the upper surface of the cylinder head and the dowel pin in its uppermost position.
    4.  
    5. Place the timing belt arrow in the direction of the engine rotation and install the timing belt. Tighten the tension pulley bolt.
    6.  
    7. Insert a hex wrench into the tension pulley hexagonal hole and hold the pulley stationary while tightening the bolt temporarily.
    8.  
    9. Turn the crankshaft two complete reverse revolutions and align the crankshaft timing pulley groove with the mark on the oil pump. Loosen the tension pulley bolt and apply tension to the timing belt.
    10.  
    11. Insert a hex wrench into the tension pulley hexagonal hole and hold the pulley stationary while torquing the bolt to 37 ft. lbs. (49 Nm).
    12.  
    13. Move the crankshaft back to about 50and#x00B0; before TDC and re-adjust the timing belt. Use a drive belt tension gauge to check the timing belt tension. The tension should be 38 +/-4 ft. lbs.; if the belt is not at the proper tension it must be re-adjust
    14.  
      1. 18.
      2.  


    Adjust the valve clearance and to complete the installation. Install the engine and check for proper operation.

    1988 and 1990 4XC1-U, 4XC1-T and 4XE1 Engines
    1. Disconnect the negative battery cable. Drain the radiator coolant into a suitable drain pan.
    2.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Place a wooden block on a suitable floor jack and place the jack under the strongest point of the oil pan, slightly raise the engine.
    2.  
    3. Remove the rear side torque rod while the engine is slightly lifted.
    4.  
    5. Remove the right side engine mount, then remove the body side mount and the engine side mount.
    6.  
    7. Loosen the power steering oil pump retaining bolt and remove the V-belt.
    8.  
    9. Remove the 4 crank pulley bolts with the engine slightly lifted.
    10.  
    11. Remove the 6 timing cover bolts and remove the timing belt cover.
    12.  
    13. Be sure that the crankshaft timing mark on the crankshaft pulley hub is aligned with the top dead center mark.
    14.  
    15. Use special crankshaft bolt tool (J-37376 or equivalent) to turn and stop the crankshaft, then remove the bolt on the end part of the crank shaft and remove the pulley.
    16.  
    17. Confirm the crankshaft is at top dead center, prior to removing the timing belt. In this state, if the notch on the camshaft pulley hub is aligned with the left upper corner of the cylinder head, the number 4 cylinder is at top dead center. If the notch on the camshaft pulley is aligned with the right upper corner of the cylinder head, the No. 1 cylinder is at top dead center.
    18.  
    19. Loosen the bolts fixing the tension pulley. Turn the tension pulley clockwise with the Allen wrench, then remove the timing belt.
    20.  


    NOTE
    Remove the camshaft pulley and make sure that there are no oil leaks or bolts on the oil seal section. Make sure that there are no water leaks from the water pump or oil leaks from the crankshaft oil seal. If water leaks or oil leaks appear, replace the oil seal or water pack packing with a new part.



    Click image to see an enlarged view

    Fig. Camshaft and crankshaft timing belt alignment marks 4XC1-U and 4XC1-T engines

    To install:

    1. Install the camshaft pulley and be sure that the camshaft pulley timing mark is aligned with the upper surface of the cylinder head and the dowel pin is in the up position. Torque the retaining bolt to 84 inch lbs. (10 Nm).
    2.  
    3. Install the crankshaft timing pulley, making sure that the woodruff key is positioned correctly.
    4.  
    5. Install the tension spring and position the long part of the tension spring to the rear of the timing case and the short end to the rear of the tension spring retaining bolt.
    6.  
    7. Install the timing belt. Be sure that the belt is installed correctly, the lettering mark in the direction of the engine rotation and install the belt in the following order; over the crankshaft timing gear, camshaft timing pulley, water pump pulley and tensioner pulley.
    8.  


    NOTE
    There must be no slack in the timing belt after it has been installed. The teeth of the belt and the teeth of the pulley must be in perfect alignment.

    1. Loosen the tension pulley bolt. Insert an Allen wrench into the tension pulley hexagonal hole. Hold the pulley stationary and temporarily tighten the bolt.
    2.  
    3. Turn the crankshaft 2 complete reverse revolutions and align the crankshaft timing pulley groove with the mark on the oil pump.
    4.  
    5. Loosen the tension pulley bolt and apply tension to the belt. Insert an Allen wrench into the tension pulley hexagonal hole. Hold the pulley stationary and torque the bolt to 37 ft. lbs. (49 Nm).
    6.  
    7. Move the crankshaft back to approximately 50and#x00B0; BTDC. Once again adjust the timing belt. Set the crankshaft at that position, use a belt tension gauge to check the timing belt tension. The belt tension should be 44 lbs.
    8.  
    9. Attach the taper face of the crankshaft pulley to the timing belt. Fasten the crankshaft pulley center bolt and torque it to 97 and 19119 ft. lbs. (131 and 19161 Nm).
    10.  
    11. Install the timing cover and torque the bolts to 84 inch lbs. (10 Nm). Be sure to pay attention to the timing belt cover bolt length. Use the following torque specifications:
    12.  
      1. Crank pulley: 5.4 and 199.5 inch lbs. (7 and 1910 Nm).
      2.  
      3. Engine mount bracket body side: 30 ft. lbs. (41 Nm).
      4.  
      5. Engine mount bracket engine side: 45 ft. lbs. (61 Nm).
      6.  
      7. Torque rod: 42 ft. lbs. (56 Nm).
      8.  


    4XE1 DOHC Engine
    1. Disconnect negative battery cable and drain cooling system. Remove the air cleaner duct hose from the common chamber.
    2.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by the 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.
    2.  
    3. Remove the power steering pump drive belt, for vehicles with air conditioners, remove the power steering pump and compressor drive belt. Loosen the 2 power steering pump adjust plates bolts.
    4.  
    5. Remove the alternator drive belt from the crank pulley side. Disconnect the clip securing the high pressure air conditioning line to the strut tower.
    6.  
    7. Remove the upper timing belt cover.
    8.  
    9. Using a suitable engine hoist, slightly raise and support the engine safely.
    10.  
    11. Remove the passenger side engine mount from the engine. Disconnect the torque rod at the firewall.
    12.  
    13. Remove the passenger side engine mounting bracket from the engine. Using special crank pulley tool J-37988 or equivalent, remove the crank pulley bolt.
    14.  
    15. Raise the passenger side of the engine, be sure that the front wheels remain on the ground while lifting the engine. Raise the engine too high will left the front wheels off the ground and may cause damage to the drive shaft universal joint.
    16.  
    17. Remove the timing belt lower cover. Remove the cranking pulley and extract up through the engine compartment. Refit the crank pulley bolt. Align the crank pulley timing gear to top dead center.
    18.  
    19. Loosen the tension pulley bolt a 1 / 2 turn counterclockwise. If the pulley bolt is loosened more than 1 / 2 a turn, the pulley will swing too far out of adjustment and may be difficult to readjust.
    20.  
    21. Mark the direction of rotation of the timing mark with a piece of chalk and remove the timing belt. Using and open end wrench, hole the camshaft from turning and remove the camshaft pulley(s).
    22.  


    NOTE
    Inspect the timing belt for signs of cracking, abnormal wear and hardening. Never expose the belt to oil, sunlight or heat. Avoid excessive bending, twisting or stretching.



    Click image to see an enlarged view

    Fig. Camshaft sprocket alignment marks 4XE1 DOHC engine



    Click image to see an enlarged view

    Fig. Crankshaft sprocket alignment marks 4XE1 DOHC engine



    Click image to see an enlarged view

    Fig. Timing belt routing 4XE1 DOHC engine



    Click image to see an enlarged view

    Fig. Timing belt positioning

    To install:

    1. Install the camshaft pulley(s) and torque the retaining bolts to 43 ft. lbs. (59 Nm). Align the camshaft pulley timing marks. Lock the camshaft pulley in position by inserting a 6mm bolt through the camshaft pulleys and into the cylinder head.
    2.  


    NOTE
    The camshaft timing pulleys have and identification mark, the I mark for the intake side and the E mark for the exhaust side.

    1. Align the crank pulley timing gear to top dead center.
    2.  
    3. Install the timing belt. Be sure that the belt is installed correctly, the lettering must be able to be read while viewing it from the passenger side fender.
    4.  
    5. The belt must be installed in the following order; over the crankshaft timing gear, water pump pulley, idle pulley, exhaust camshaft pulley, intake camshaft pulley and tensioner pulley.
    6.  


    NOTE
    There must be no slack in the timing belt after it has been installed. The teeth of the belt and the teeth of the pulley must be in perfect alignment.

    1. Loosen the tensioner bolt and apply spring force to the belt. If reusing the old belt, do not tension the belt with more than spring force applied. When a new belt is being used, push the tension pulley in the direction of the belt tension. The tensioner pulley retaining bolt should be torqued to 17 ft. lbs. (24 Nm).
    2.  
    3. Keep the tension pulley from turning while fastening the fixing bolt in order to prevent excessively high low tension of the timing belt.
    4.  
    5. Rotate the crankshaft 2 turns normally and make sure that the notch on cylinder number 1 matches the scale on the timing cover match as well as the mark on the cam pulley. If it does not match them, repeat this procedure again from Step number 1.
    6.  
    7. Turn the crankshaft by 60and#x00B0; normally and measure the deflection of the timing belt. Be sure that it is within the specified range. If the deflection is not within the specified values, repeat the this procedure from Step 4. The belt tension should be as follows:
    8.  
      1. New belt: 0.28 and 190.33 lbs.
      2.  
      3. Old belt: 0.35 and 190.41 lbs.
      4.  

    9. Attach the taper face of the crankshaft pulley to the timing belt. Fasten the crankshaft pulley center bolt and torque it to 123 ft. lbs. (170 Nm).
    10.  
    11. Install the timing cover and torque the bolts to 84 inch lbs. (9.5 Nm).
    12.  

    4ZD1 and 4ZE1 Engines
    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.  


    NOTE
    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.  



    Click image to see an enlarged view

    Fig. Timing belt and tensioner assembly 4ZC1-T, 4ZD1 and 4ZE1 engines



    Click image to see an enlarged view

    Fig. Timing belt tensioner loosen bolt and then tighten



    Click image to see an enlarged view

    Fig. Crankshaft pulley alignment 4ZC1-T, 4ZD1 and 4ZE1 engines



    Click image to see an enlarged view

    Fig. Camshaft pulley alignment 4ZC1-T, 4ZD1 and 4ZE1 engines

    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.  

    C223 and C223-T Engines
    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 the 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.  


    NOTE
    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.  



    Click image to see an enlarged view

    Fig. Injection pump and camshaft alignment marks C223 diesel engine



    Click image to see an enlarged view

    Fig. Remove the timing belt holder C223 diesel engine



    Click image to see an enlarged view

    Fig. Injection pump alignment marks C223 diesel engine



    Click image to see an enlarged view

    Fig. Tensioner pulley bolt sequence C223 diesel engine



    Click image to see an enlarged view

    Fig. After removing the timing cover, make sure the crankshaft is in the No. 1 cylinder TDC position

    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 and 1936 ft. lbs. (30 and 1948 Nm).
    12.  
    13. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90and#x00B0; 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 and 1994 ft. lbs. (108 and 19128 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 and 1955 lbs.
    20.  
    21. Install the timing belt cover.
    22.  
    23. Connect the negative battery cable.
    24.  

    4FB1 Diesel Engine
    1. Open the hood and disconnect the battery. Drain the radiator system.
    2.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by the 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 lower engine shrouds.
    2.  
    3. Remove the fan shroud, V-belt, cooling fan and pulley.
    4.  
    5. Remove the 10 retaining bolts on the upper dust cover and remove the cover.
    6.  
    7. Remove the bypass hose.
    8.  
    9. With the piston in the No. 1 cylinder at TDC, make sure the setting mark on the pump pulley is in alignment with the front plate, then lock the pulley with an 8mm 1.25 pitch bolt.
    10.  
    11. Remove the cam cover. Loosen the adjusting screws so that the rocker arms are held in a free state. Lock the camshaft by fitting a plate to the slit in the rear end of the camshaft.
    12.  
    13. Remove the damper pulley after making sure the piston in No. 1 is at TDC.
    14.  
    15. Remove the lower dust cover, then remove the timing belt holder.
    16.  
    17. Remove the tension spring. Loosen the tension pulley and plate bolts and remove the timing belt.
    18.  



    Click image to see an enlarged view

    Fig. Install a camshaft fixing plate to the slit in the end of the camshaft 4FB1 diesel engine



    Click image to see an enlarged view

    Fig. After removing the timing cover, make sure the crankshaft is in the No. 1 cylinder TDC position

    To install:

    1. Remove the bolt locking the camshaft pulley and remove the pulley from the camshaft. Put the pulley back on the shaft, but only tighten the bolts enough to allow the pulley to be turned by hand.
    2.  
    3. Install the new timing belt, making sure the cogs on the pulley and the belt are engaged properly. The crankshaft should not be turned.
    4.  
    5. Concentrate belt looseness on the tension pulley, then depress the tension pulley with your fingers and install the tension spring. Semi-tighten the bolts in numerical sequence to prevent movement of the tension pulley.
    6.  
    7. Tighten the camshaft pulley bolts.
    8.  
    9. Remove the injection pump pulley lock bolt.
    10.  
    11. Remove the locking plate on the end of the camshaft.
    12.  
    13. Install the damper pulley on the hub and make sure the No. 1 piston is still at TDC.
    14.  


    CAUTION
    Do not turn the crankshaft in an attempt to make an adjustment.

    1. Make sure the injection pump pulley mark is in alignment with the mark on the plate.
    2.  
    3. Loosen the tensioner pulley and plate bolts. Concentrate the looseness of the belt on the tensioner, then tighten the bolts on numerical sequence. Torque the bolts to:
    4.  
      1. Bolt No. 1 to 11 and 1918 ft. lbs. (15 and 1925 Nm)
      2.  
      3. Bolt No. 2 to 11 and 1918 ft. lbs. (15 and 1925 Nm)
      4.  
      5. Bolt No. 3 to 47 and 1961 ft. lbs. (63 and 1983 Nm)
      6.  

    5. Check valve adjustment and install the cam cover.
    6.  
    7. Remove the damper pulley and install the belt holder in position away from the timing belt.
    8.  
    9. Install the bypass hose and dust covers.
    10.  
    11. Install the damper pulley and reverse removal Steps 15.
    12.  
    13. Refill the cooling system.
    14.  

     
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