REMOVAL & INSTALLATION CAUTION:This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. TIMING BELT NOTE:Some procedures may differ slightly due to engine construction. Removal Disconnect negative battery cable. Remove all necessary air ducts. Position No. 1 cylinder at TDC of compression stroke. Align timing marks. See Fig. 1. Remove fan and fan shroud. Remove accessory drive belts. Remove water pump pulley. If necessary, remove radiator and splash guard. Prevent engine from rotating, and remove crankshaft timing pulley. Remove upper and lower timing belt covers. See Fig. 2. Remove spring from tension pulley. Loosen adjusting bolt and move pulley toward water pump. Remove timing belt. CAUTION:Ensure No. 1 cylinder is at TDC when rotating camshaft, or damage may result. Fig. 1: Aligning Timing Marks Courtesy of ISUZU MOTOR CO. Fig. 2: Exploded View of Timing Belt & Components Courtesy of ISUZU MOTOR CO.
Inspection Handle timing belt carefully. Avoid twisting or kinking belt. DO NOT allow belt to become contaminated by water, oil, dirt or other contaminates. Inspect belt for cracks or damage. Replace, if necessary. On 2.0L engines, measure outside diameter of crankshaft, camshaft and oil pump sprockets. If specifications are exceeded, replace sprocket(s). See TIMING SPROCKET SPECIFICATIONS (2.0L) table. On all engines, measure tension pulley spring length and force. On 2.3L and 2.6L engine, spring length should not exceed 2.76" (70.2 mm) and spring force should not be less than 60-106 lbs. (27-48 kg). On 2.0L, spring length should not exceed 3.11" (79 mm), and spring force should not be less than 53-57 lbs. (24-26 kg). On all engines, replace tension pulley spring if not within specification. TIMING SPROCKET SPECIFICATIONS (2.0L) ApplicationStandard - In. (Mm)Limit - In. (Mm) Camshaft5.2025.198 (132.03)(131.93) Crankshaft2.5742.570 (65.33)(65.23) Oil Pump4.4854.481 (113.84)(113.74)
IMPORTANT:If distributor has been removed from cylinder head, install distributor with No. 4 cylinder at TDC of the compression stroke.
Pull tensioner fully toward water pump side, and temporarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC on compression stroke by rotating crankshaft until keyway aligns with mark on front crankshaft seal housing (12 o'clock). Rotate camshaft until timing mark on cam gear (arrow) aligns with mark on upper camshaft cover (notch). See Fig. 1.
Position timing belt over crankshaft sprocket, oil pump sprocket, camshaft sprocket and tensioner in that order. Ensure belt is positioned in sequence given and without slack between sprockets. Loosen tensioner pulley adjusting bolt allowing spring tension to tighten belt. Tighten adjusting bolt temporarily.
Temporarily install crankshaft pulley bolt and rotate crankshaft 2 complete revolutions in opposite direction of engine rotation, until marks on crankshaft and front oil seal retainer are aligned again. See Fig. 1. Loosen tensioner lock bolt, allowing tensioner spring to fully adjust tension. Tighten tensioner lock bolt.
Install timing belt covers. To complete installation, reverse removal procedures. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension.
Fig. 3: Installing Belt Guide
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Thursday, November 25th, 2010 AT 4:55 AM