Isuzu_Rodeo_Rodeo_Sport_1997-2004

Cylinder Head

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following: Negative battery cableIntake Air Temperature (IAT) sensor connectorPositive Crankcase Ventilation (PCV) valve and hoseAir intake assemblyUpper radiator hoseAccessory drive beltExhaust front pipeAlternator and bracketsCrankshaft Position (CKP) sensor connectorKnock sensor connectorHeater hosesWater bypass hoseFuel linesEvaporative Emissions (EVAP) valve connectorCanister hoseIntake manifoldEngine wiring harness connectors at left rear of the engine compartmentPower steering pump pressure switch connectorFront coverSpark plugs and wiresCamshaft Position (CMP) sensorValve coverTiming belt. Refer to the Timing Belt unit repair section.Timing belt idler pulleysTiming belt rear coverOil pressure switch connectorCamshaftsCylinder head. Remove the bolts in reverse of the tightening sequence.

    Negative battery cable
     
    Intake Air Temperature (IAT) sensor connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Air intake assembly
     
    Upper radiator hose
     
    Accessory drive belt
     
    Exhaust front pipe
     
    Alternator and brackets
     
    Crankshaft Position (CKP) sensor connector
     
    Knock sensor connector
     
    Heater hoses
     
    Water bypass hose
     
    Fuel lines
     
    Evaporative Emissions (EVAP) valve connector
     
    Canister hose
     
    Intake manifold
     
    Engine wiring harness connectors at left rear of the engine compartment
     
    Power steering pump pressure switch connector
     
    Front cover
     
    Spark plugs and wires
     
    Camshaft Position (CMP) sensor
     
    Valve cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Timing belt idler pulleys
     
    Timing belt rear cover
     
    Oil pressure switch connector
     
    Camshafts
     
    Cylinder head. Remove the bolts in reverse of the tightening sequence.
     

  8.  

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.2L (VIN D) engine


NOTE
Use new cylinder head bolts for assembly.

  1. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows: Step 1: 18 ft. lbs. (25 Nm)Step 2: Plus 90 degreesStep 3: Plus 90 degreesStep 4: Plus 90 degrees
    1. Step 1: 18 ft. lbs. (25 Nm)
    2.  
    3. Step 2: Plus 90 degrees
    4.  
    5. Step 3: Plus 90 degrees
    6.  
    7. Step 4: Plus 90 degrees
    8.  

  2.  
  3. Install or connect the following: CamshaftsOil pressure switch connectorTiming belt rear coverTiming belt idler pulleys. Tighten the bolts to 18 ft. lbs. (25 Nm).Timing beltValve coverCMP sensorSpark plugs and wiresFront coverPower steering pump pressure switch connectorEngine wiring harness connectors at left rear of the engine compartmentIntake manifoldCanister hoseEVAP valve connectorFuel linesWater bypass hoseHeater hosesKnock sensor connectorCKP sensor connectorAlternator and bracketsExhaust front pipeAccessory drive beltUpper radiator hoseAir intake assemblyPCV valve and hoseIAT sensor connectorNegative battery cable

    Camshafts
     
    Oil pressure switch connector
     
    Timing belt rear cover
     
    Timing belt idler pulleys. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Timing belt
     
    Valve cover
     
    CMP sensor
     
    Spark plugs and wires
     
    Front cover
     
    Power steering pump pressure switch connector
     
    Engine wiring harness connectors at left rear of the engine compartment
     
    Intake manifold
     
    Canister hose
     
    EVAP valve connector
     
    Fuel lines
     
    Water bypass hose
     
    Heater hoses
     
    Knock sensor connector
     
    CKP sensor connector
     
    Alternator and brackets
     
    Exhaust front pipe
     
    Accessory drive belt
     
    Upper radiator hose
     
    Air intake assembly
     
    PCV valve and hose
     
    IAT sensor connector
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) sensor connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Air intake assembly
     
    Upper radiator hose
     
    Accessory drive belt
     
    Exhaust front pipe
     
    Alternator and brackets
     
    Crankshaft Position (CKP) sensor connector
     
    Knock sensor connector
     
    Heater hoses
     
    Water bypass hose
     
    Fuel lines
     
    Evaporative Emissions (EVAP) valve connector
     
    Canister hose
     
    Intake manifold
     
    Engine wiring harness connectors at left rear of the engine compartment
     
    Power steering pump pressure switch connector
     
    Front cover
     
    Spark plugs and wires
     
    Camshaft Position (CMP) sensor
     
    Valve cover
     
    Timing belt. Refer to the Timing Belt procedure.
     
    Timing belt idler pulleys
     
    Timing belt rear cover
     
    Oil pressure switch connector
     
    Camshafts
     
    Cylinder head. Remove the bolts in reverse of the tightening sequence.
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.2L (VIN D) engine


NOTE
Use new cylinder head bolts for assembly.

  1. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm)
    2.  
    3. Step 2: Plus 90 degrees
    4.  
    5. Step 3: Plus 90 degrees
    6.  
    7. Step 4: Plus 90 degrees
    8.  

  2.  
  3. Install or connect the following:

    Camshafts
     
    Oil pressure switch connector
     
    Timing belt rear cover
     
    Timing belt idler pulleys. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Timing belt
     
    Valve cover
     
    CMP sensor
     
    Spark plugs and wires
     
    Front cover
     
    Power steering pump pressure switch connector
     
    Engine wiring harness connectors at left rear of the engine compartment
     
    Intake manifold
     
    Canister hose
     
    EVAP valve connector
     
    Fuel lines
     
    Water bypass hose
     
    Heater hoses
     
    Knock sensor connector
     
    CKP sensor connector
     
    Alternator and brackets
     
    Exhaust front pipe
     
    Accessory drive belt
     
    Upper radiator hose
     
    Air intake assembly
     
    PCV valve and hose
     
    IAT sensor connector
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following: Negative battery cableHoodEngine coverMass Air Flow (MAF) sensor connectorIntake Air Temperature (IAT) sensor connectorPositive Crankcase Ventilation (PCV) valve and hoseAir cleaner assemblyManifold Absolute Pressure (MAP) sensor connectorVacuum Switching Valve (VSV) connector and vacuum lineFuel injector connectorsThrottle Position (TP) sensor connectorIdle Air Control (IAC) valve connectorIgnition coilsBrake booster vacuum lineCanister purge vacuum lineDuty solenoid valveFuel linesIntake manifoldRadiator hosesEngine coolant manifoldUpper fan shroudAccessory drive belt and tensionerCooling fan and pulleyAlternatorIdler pulleyPower steering pump and bracketA/C compressorCrankshaft pulleyOil cooler hosesTiming belt coverValve coversTiming belt. Refer to the Timing Belt Unit Repair Section.Left and right exhaust front pipesOil dipstick tubeCylinder heads

    Negative battery cable
     
    Hood
     
    Engine cover
     
    Mass Air Flow (MAF) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Air cleaner assembly
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Vacuum Switching Valve (VSV) connector and vacuum line
     
    Fuel injector connectors
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Ignition coils
     
    Brake booster vacuum line
     
    Canister purge vacuum line
     
    Duty solenoid valve
     
    Fuel lines
     
    Intake manifold
     
    Radiator hoses
     
    Engine coolant manifold
     
    Upper fan shroud
     
    Accessory drive belt and tensioner
     
    Cooling fan and pulley
     
    Alternator
     
    Idler pulley
     
    Power steering pump and bracket
     
    A/C compressor
     
    Crankshaft pulley
     
    Oil cooler hoses
     
    Timing belt cover
     
    Valve covers
     
    Timing belt. Refer to the Timing Belt Unit Repair Section.
     
    Left and right exhaust front pipes
     
    Oil dipstick tube
     
    Cylinder heads
     

  8.  

To install:



Click image to see an enlarged view

Fig. Right (1) and left (2) head gasket identification mark locations-3.2L DOHC engine


NOTE
Use new head bolts when installing the cylinder head.


NOTE
The left and right cylinder head gaskets are not interchangeable.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.2L DOHC and 3.5L engines

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows: Step 1: 21 ft. lbs. (29 Nm)Step 2: 47 ft. lbs. (64 Nm)
    1. Step 1: 21 ft. lbs. (29 Nm)
    2.  
    3. Step 2: 47 ft. lbs. (64 Nm)
    4.  

  2.  
  3. Install or connect the following: Oil dipstick tubeLeft and right exhaust front pipesTiming beltValve coversTiming belt coverOil cooler hosesCrankshaft pulley. Tighten the pulley bolt to 123 ft. lbs. (167 Nm).A/C compressorPower steering pump and bracket. Tighten the bolts to 34 ft. lbs. (46 Nm).Idler pulleyAlternatorCooling fan and pulleyAccessory drive belt and tensionerUpper fan shroudEngine coolant manifoldRadiator hosesIntake manifoldFuel linesDuty solenoid valveCanister purge vacuum lineBrake booster vacuum lineIgnition coilsIAC valve connectorTP sensor connectorFuel injector connectorsVSV connector and vacuum lineMAP sensor connectorAir cleaner assemblyPCV valve and hoseIAT sensor connectorMAF sensor connectorEngine coverHoodNegative battery cable

    Oil dipstick tube
     
    Left and right exhaust front pipes
     
    Timing belt
     
    Valve covers
     
    Timing belt cover
     
    Oil cooler hoses
     
    Crankshaft pulley. Tighten the pulley bolt to 123 ft. lbs. (167 Nm).
     
    A/C compressor
     
    Power steering pump and bracket. Tighten the bolts to 34 ft. lbs. (46 Nm).
     
    Idler pulley
     
    Alternator
     
    Cooling fan and pulley
     
    Accessory drive belt and tensioner
     
    Upper fan shroud
     
    Engine coolant manifold
     
    Radiator hoses
     
    Intake manifold
     
    Fuel lines
     
    Duty solenoid valve
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Ignition coils
     
    IAC valve connector
     
    TP sensor connector
     
    Fuel injector connectors
     
    VSV connector and vacuum line
     
    MAP sensor connector
     
    Air cleaner assembly
     
    PCV valve and hose
     
    IAT sensor connector
     
    MAF sensor connector
     
    Engine cover
     
    Hood
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Engine cover
     
    Mass Air Flow (MAF) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Air cleaner assembly
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Vacuum Switching Valve (VSV) connector and vacuum line
     
    Fuel injector connectors
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Ignition coils
     
    Brake booster vacuum line
     
    Canister purge vacuum line
     
    Duty solenoid valve
     
    Fuel lines
     
    Intake manifold
     
    Radiator hoses
     
    Engine coolant manifold
     
    Upper fan shroud
     
    Accessory drive belt and tensioner
     
    Cooling fan and pulley
     
    Alternator
     
    Idler pulley
     
    Power steering pump and bracket
     
    A/C compressor
     
    Crankshaft pulley
     
    Oil cooler hoses
     
    Timing belt cover
     
    Valve covers
     
    Timing belt. Refer to the Timing Belt Procedure.
     
    Left and right exhaust front pipes
     
    Oil dipstick tube
     
    Cylinder heads
     

  8.  

To install:

Click image to see an enlarged view

Fig. Right (1) and left (2) head gasket identification mark locations-3.2L engines


NOTE
Use new head bolts when installing the cylinder head.


NOTE
The left and right cylinder head gaskets are not interchangeable.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.2L engines

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 21 ft. lbs. (29 Nm)
    2.  
    3. Step 2: 47 ft. lbs. (64 Nm)
    4.  

  2.  
  3. Install or connect the following:

    Oil dipstick tube
     
    Left and right exhaust front pipes
     
    Timing belt
     
    Valve covers
     
    Timing belt cover
     
    Oil cooler hoses
     
    Crankshaft pulley. Tighten the pulley bolt to 123 ft. lbs. (167 Nm).
     
    A/C compressor
     
    Power steering pump and bracket. Tighten the bolts to 34 ft. lbs. (46 Nm).
     
    Idler pulley
     
    Alternator
     
    Cooling fan and pulley
     
    Accessory drive belt and tensioner
     
    Upper fan shroud
     
    Engine coolant manifold
     
    Radiator hoses
     
    Intake manifold
     
    Fuel lines
     
    Duty solenoid valve
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Ignition coils
     
    IAC valve connector
     
    TP sensor connector
     
    Fuel injector connectors
     
    VSV connector and vacuum line
     
    MAP sensor connector
     
    Air cleaner assembly
     
    PCV valve and hose
     
    IAT sensor connector
     
    MAF sensor connector
     
    Engine cover
     
    Hood
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableHoodEngine coverMass Air Flow (MAF) sensor connectorIntake Air Temperature (IAT) sensor connectorPositive Crankcase Ventilation (PCV) valve and hoseAir cleaner assemblyManifold Absolute Pressure (MAP) sensor connectorVacuum Switching Valve (VSV) connector and vacuum lineFuel injector connectorsThrottle Position (TP) sensor connectorIdle Air Control (IAC) valve connectorIgnition coilsBrake booster vacuum lineCanister purge vacuum lineDuty solenoid valveFuel linesIntake manifoldRadiator hosesEngine coolant manifoldUpper fan shroudAccessory drive belt and tensionerCooling fan and pulleyAlternatorIdler pulleyPower steering pump and bracketA/C compressorCrankshaft pulleyOil cooler hosesTiming belt coverValve coversTiming belt. Refer to the Timing Belt Unit Repair Section.Left and right exhaust front pipesOil dipstick tubeCylinder heads

    Negative battery cable
     
    Hood
     
    Engine cover
     
    Mass Air Flow (MAF) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Air cleaner assembly
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Vacuum Switching Valve (VSV) connector and vacuum line
     
    Fuel injector connectors
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Ignition coils
     
    Brake booster vacuum line
     
    Canister purge vacuum line
     
    Duty solenoid valve
     
    Fuel lines
     
    Intake manifold
     
    Radiator hoses
     
    Engine coolant manifold
     
    Upper fan shroud
     
    Accessory drive belt and tensioner
     
    Cooling fan and pulley
     
    Alternator
     
    Idler pulley
     
    Power steering pump and bracket
     
    A/C compressor
     
    Crankshaft pulley
     
    Oil cooler hoses
     
    Timing belt cover
     
    Valve covers
     
    Timing belt. Refer to the Timing Belt Unit Repair Section.
     
    Left and right exhaust front pipes
     
    Oil dipstick tube
     
    Cylinder heads
     

  6.  

To install:



Click image to see an enlarged view

Fig. Right (1) and left (2) head gasket identification mark locations-3.5L engine


NOTE
Use new head bolts when installing the cylinder head. Do not apply oil to the head bolt threads.


NOTE
The left and right cylinder head gaskets are not interchangeable.

  1. Install the cylinder heads with new gaskets. Tighten the bolts to 47 ft. lbs. (64 Nm).
  2.  
  3. Install or connect the following: Oil dipstick tubeLeft and right exhaust front pipesTiming beltValve coversTiming belt coverOil cooler hosesCrankshaft pulley. Tighten the pulley bolt to 123 ft. lbs. (167 Nm).A/C compressorPower steering pump and bracket. Tighten the bolts to 34 ft. lbs. (46 Nm).Idler pulleyAlternatorCooling fan and pulleyAccessory drive belt and tensionerUpper fan shroudEngine coolant manifoldRadiator hosesIntake manifoldFuel linesDuty solenoid valveCanister purge vacuum lineBrake booster vacuum lineIgnition coilsIAC valve connectorTP sensor connectorFuel injector connectorsVSV connector and vacuum lineMAP sensor connectorAir cleaner assemblyPCV valve and hoseIAT sensor connectorMAF sensor connectorEngine coverHoodNegative battery cable

    Oil dipstick tube
     
    Left and right exhaust front pipes
     
    Timing belt
     
    Valve covers
     
    Timing belt cover
     
    Oil cooler hoses
     
    Crankshaft pulley. Tighten the pulley bolt to 123 ft. lbs. (167 Nm).
     
    A/C compressor
     
    Power steering pump and bracket. Tighten the bolts to 34 ft. lbs. (46 Nm).
     
    Idler pulley
     
    Alternator
     
    Cooling fan and pulley
     
    Accessory drive belt and tensioner
     
    Upper fan shroud
     
    Engine coolant manifold
     
    Radiator hoses
     
    Intake manifold
     
    Fuel lines
     
    Duty solenoid valve
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Ignition coils
     
    IAC valve connector
     
    TP sensor connector
     
    Fuel injector connectors
     
    VSV connector and vacuum line
     
    MAP sensor connector
     
    Air cleaner assembly
     
    PCV valve and hose
     
    IAT sensor connector
     
    MAF sensor connector
     
    Engine cover
     
    Hood
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine. Check for leaks and proper operation.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Exhaust manifold
     
    Intake manifold
     
    Camshafts
     
    Oil dipstick tube
     
    Engine coolant manifold
     
    Fuel injector connectors
     
    Fuel rail joint
     
    Fuel lines
     
    Radiator hoses
     
    Water manifold guide tube
     

  8.  
  9. Loosen the head bolts in the reverse of the tightening sequence. Remove the cylinder heads.
    NOTE
    Do not rotate the crankshaft while the head(s) is removed. Once removed, place the head on wood blocks.

  10.  
  11. Installation is the reverse of removal. The head gaskets are marked for left (L) and right (R). Use new head gaskets. Use new head bolts. Do not apply any lubricant to the head bolts. Tighten the M11 bolts, in sequence, to:
    1. Step 1: 21 ft. lbs. (29 Nm)
    2.  
    3. Step 2: 47 ft. lbs. (64 Nm)
    4.  

  12.  
  13. Tighten the M8 bolt to 15 ft. lbs. (21 Nm).

    Click image to see an enlarged view

    Fig. Head bolt torque sequence-3.5L VIN Y engine. Note the small bolt at the right, marked 1, is the M8 bolt

  14.  

 
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