Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 711

6A–25

ENGINE MECHANICAL

Exhaust Manifold RH

Removal

035RX016

Legend

(1) Exhaust Front Pipe RH
(2) O

2

 Sensors

(3) Torsion Bar

(4) Front Propeller Shaft
(5) Transfer Case Skid Plate
(6) 3rd Crossmember

1. Disconnect battery ground cable.
2. Remove transfer case skid plate.
3. Remove 3rd  crossmember.
4. Remove torsion bar and front propeller shaft. Refer to

removal procedure in Front Suspension section.

5. Disconnect front Heated oxygen (O

2

) sensor

connectors.

6. Remove front exhaust flange pipe three stud nuts and

two rear flange nuts then disconnect exhaust pipe.

7. Remove heat protector two fixing bolts then the heat

protector.

8. Remove exhaust gas recirculation (EGR) pipe fixing

bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.

9. Remove exhaust manifolds eight fixing nuts and the

exhaust manifold.

Installation

1. Install exhaust manifold and tighten bolts to the

specified torque.

Torque : 52 N·m (38 lb ft)

2. Install the EGR pipe, tighten bolt and nut on exhaust

manifold to specified torque.

Torque : 28 N·m (21 lb ft)

Tighten nut to EGR valve to the specified torque.

Torque : 44 N·m (33 lb ft)

Tighten the bolt for EGR pipe bracket to specified
torque.

Torque : 25 N·m (18 lb ft)

3. Install heat protector

6A–26

ENGINE MECHANICAL

4. Install front exhaust flange pipe and tighten three stud

nuts and rear two nuts to the specified torque.

Torque:
Stud nuts: 67 N·m (49 lb ft)
Nuts: 57 N·m (42 lb ft)

5. Reconnect O

2

 Sensor harness connector.

6. Install the torsion bar and readjust the vehicle height.

Refer to installation and vehicle height adjustment
procedure for Front Suspension.

7. Install front propeller shaft.

Refer to installation procedue in Front suspension
section.

8. Install 3rd crossmember.
9. Install transfer case skid plate.

Crankshaft Pulley

Removal

1. Disconnect battery ground cable.
2. Remove air cleaner assembly.

013RY00001

Legend

(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Mass Air Flow Sensor

3. Remove radiator upper fan shroud from radiator.

4.  Move serpentine belt tensioner to loose side using

wrench then remove serpentine belt.

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Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Driver Belt

5. Remove cooling fan assembly four fixing nuts, then

the cooling fan assembly.

6. Remove crankshaft pulley assembly using J-8614-01

crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.

Installation

1. Install crankshaft pulley using J-8614-01 crankshaft

holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.

Torque : 167 N·m (123 lb ft)

6A–27

ENGINE MECHANICAL

2. Install cooling fan assembly and tighten bolts/nuts to

the specified torque.

Torque : 22 N·m (16 lb ft) for fan pulley and fan
bracket.

Torque : 10 N·m (87 lb in) for fan and clutch
assembly.

3. Move serpentine belt tensioner to loose side using

wrench, then install serpentine belt to normal
position.

4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

Timing Belt

Removal

1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench

then remove drive belt.

850RW001

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt

5. Remove cooling fan assembly four nuts, then the

cooling fan assembly.

6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.

10. Remove crankshaft pulley assembly using J-8614-01

crankshaft holder, hold crankshaft pulley remove
center bolt, then the pulley.

11. Remove right side timing belt cover then left side

timing belt cover.

12. Remove lower timing belt cover
13. Remove pusher.

CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.

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Legend

(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin

14. Remove timing belt.

CAUTION:
1. Do not bend or twist the belt, otherwise its core

could be damaged. The belt should not be bent at
a radius less than 30 mm.

2. Do not allow oil or other chemical substances to

come in contact with the belt. They will shorten
the life.

3. Do not attempt to pry or stretch the belt with a

screw driver or any other tool during installation.

4. Store timing belt in a cool and dark place. Never

expose the belt direct sunlight or heat.

6A–28

ENGINE MECHANICAL

Installation

NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.

014RW005

Legend

(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt

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Legend

(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side

1. Install timing belt.

1. Align groove of crankshaft timing pulley (2) with

mark on oil pump (1).
Align the mark on the crankshaft timing pulley (3)
with alignment mark (white dotted line) on the tim-
ing belt (4).
Secure the belt with a double clip or equivalent
clip.

NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.

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Legend

(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt