Isuzu Rodeo UE. Manual - part 128

6A–1

ENGINE MECHANICAL (X22SE 2.2L)

RODEO

ENGINE

CONTENTS

Engine Mechanical

6A–1

. . . . . . . . . . . . . . . . . . . . . . 

Engine Cooling

6B–1

. . . . . . . . . . . . . . . . . . . . . . . . . 

Engine Fuel

6C–1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Engine Electrical

6D1–1

. . . . . . . . . . . . . . . . . . . . . . . . 

Ignition System

6D2–1

. . . . . . . . . . . . . . . . . . . . . . . . . 

Starting and Charging System

6D3–1

. . . . . . . . . . . . 

Driveability and Emissions

6E1–1

. . . . . . . . . . . . . . . . 

Engine Exhaust

6F–1

. . . . . . . . . . . . . . . . . . . . . . . . . 

Engine Lubrication

6G–1

. . . . . . . . . . . . . . . . . . . . . . 

Engine Speed Control System

6H–1

. . . . . . . . . . . . 

Induction

6J–1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

ENGINE MECHANICAL (X22SE 2.2L)

CONTENTS

Service Precaution

6A–2

. . . . . . . . . . . . . . . . . . . . . . 

General Description

6A–2

. . . . . . . . . . . . . . . . . . . . . 

Engine Diagnosis

6A–3

. . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Head Cover

6A–16

. . . . . . . . . . . . . . . . . . . . 

Removal

6A–16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Exhaust Manifold

6A–18

. . . . . . . . . . . . . . . . . . . . . . . . 

Removal

6A–18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Crankshaft Pulley

6A–19

. . . . . . . . . . . . . . . . . . . . . . . 

Removal

6A–19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Intake Manifold

6A–20

. . . . . . . . . . . . . . . . . . . . . . . . . 

Removal

6A–20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Head Assembly

6A–22

. . . . . . . . . . . . . . . . . 

Removal

6A–22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Timing Belt

6A–28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Removal

6A–28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Camshaft

6A–32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Removal

6A–32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Engine Assembly

6A–35

. . . . . . . . . . . . . . . . . . . . . . . . 

Removal

6A–36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Head

6A–39

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Head and Associated Parts

6A–39

. . . . . 

Disassembly

6A–39

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–40

. . . . . . . . . . . . . . . . . . 

Reassembly

6A–41

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Valve Spring, Valve, Valve Guide

6A–42

. . . . . . . . . . 

Valve Spring, Valve, Valve Guide and
 Associated Parts

6A–42

. . . . . . . . . . . . . . . . . . . . . . 

Disassembly

6A–42

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–43

. . . . . . . . . . . . . . . . . . 

Reassembly

6A–44

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Camshaft

6A–45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Camshaft and Associated Parts

6A–45

. . . . . . . . . 

Disassembly

6A–45

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Reassembly

6A–46

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Crankshaft

6A–47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Crankshaft and Associated Parts

6A–47

. . . . . . . . 

Disassembly

6A–47

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–48

. . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–49

. . . . . . . . . . . . . . . . . . 

Reassembly

6A–50

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Piston and Connecting Rod

6A–53

. . . . . . . . . . . . . . . 

Piston, Connecting Rod and Associate
 Parts

6A–53

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembly

6A–53

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–54

. . . . . . . . . . . . . . . . . . 

Reassembly

6A–56

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Block

6A–57

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Block and Associated Parts

6A–57

. . . . . 

Disassembly

6A–58

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–58

. . . . . . . . . . . . . . . . . . 

Reassembly

6A–59

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Head Cover

6A–60

. . . . . . . . . . . . . . . . . . . . 

Cylinder Head Cover and Associated parts

6A–60

Removal

6A–61

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

6A–61

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Balance Unit Assembly

6A–63

. . . . . . . . . . . . . . . . . . 

Balance Unit Assembly Associated Parts

6A–63

. 

Disassembly

6A–64

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Adjustment

6A–64

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

Reassembly

6A–66

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Main Data and Specifications

6A–68

. . . . . . . . . . . . . 

Special Tools

6A–73

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

6A–2

ENGINE MECHANICAL (X22SE 2.2L)

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

General Description

Engine Cleanliness And Care

An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.

f

A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.

f

Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.

f

At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.

f

Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

f

The four cylinders of this engine are identified by
numbers; cylinders 1, 2, 3 and 4, as counted from
crankshaft pulley.

General Information on Engine Service

The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:

f

When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick up unit.

f

The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.

f

Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.

Cylinder Block

The cylinder block is made of cast iron. The crankshaft is
supported by five bearings. The bearing cap is made of
nodular cast iron.

Cylinder Head

The cylinder head is made of aluminum alloy casting with
a spark plug in the center.

Valve Train

Valve system is direct–acting invertered bucket tappet.
The valves clearance adjustment are hydraulic.
Hydraulic valve lash adjustment, no adjustment
necessary.

Intake Manifold

The intake manifold is made of aluminum alloy.

Exhaust Manifold

The exhaust manifold is made of high Si–Mo nodular iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of case–harded steel. The connecting rods are made of
cast iron. The connecting rod bearings are made of steel
backed with babbitt metal.

Crankshaft and Bearings

The crankshaft is made of nodular cast iron. Pins and
journals are graded for correct size selection for their
bearing.

Balance Shaft

Type is lanchester (twin counter–rotating shafts). The
balance shafts are made of cast iron and gears are hard
faced. The housing is made of cast iron. Backlash
adjustment method is shim–balancer housing to block
(selective fit).

6A–3

ENGINE MECHANICAL (X22SE 2.2L)

Engine Diagnosis

Hard Starting

1. Starting Motor Does Not Turn Over
Trouble Shooting Procedure
Turn on headlights and starter switch.

Condition

Possible cause

Correction

Headlights go out or dim
considerably

Battery run down or under charged

Recharge or replace battery

considerably

Terminals poorly connected

Clean battery posts and terminals
and connect properly

Starting motor coil circuit shorted

Overhaul or replace

Starting motor defective

Overhaul or replace

2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect a high tension cable from any spark plug.
Connect the spark plug tester J–26792 (ST–125), crank
the engine, and check if a spark is generated in the spark
plug tester.  Before cranking the engine, make sure that
the spark plug tester is properly grounded. To avoid elec-
trical shock, do not touch the high tension cable while the
engine is running.

Condition

Possible cause

Correction

Spark jumps across gap

Spark plug defective

Clean, adjust spark gap or replace

Ignition timing incorrect

Refer to Ignition System

Fuel not reaching fuel injector(s) or
engine

Refer to item 3 (Trouble in fuel
system)

Valve timing incorrect

Adjust

Engine lacks compression

Refer to item 4 (Engine lacks
compression)

No sparking takes place

Ignition coil disconnected or broken

Connect properly or replace

Electronic Ignition System with
module

Replace

Poor connections in engine harness

Correct

Powertrain Control Module cable
disconnected or defective

Correct or replace

6A–4

ENGINE MECHANICAL (X22SE 2.2L)

3. Trouble In Fuel System

Condition

Possible cause

Correction

Starting motor turns over and spark
occurs but engine does not start

Fuel tank empty

Fill

occurs but engine does not start.

Water in fuel system

Clean

Fuel filter clogged

Replace filter

Fuel pipe clogged

Clean or replace

Fuel pump defective

Replace

Fuel pump circuit open

Correct or replace

Evaporative Emission Control
System circuit clogged

Correct or replace

Multiport Fuel Injection System faulty

Refer to “Electronic Fuel Injection”
section

4. Engine Lacks Compression

Condition

Possible cause

Correction

Engine lacks compression

Spark plug loosely fitted or spark
plug gasket defective

Tighten to specified torque or replace
gasket

Valve timing incorrect

Adjust

Cylinder head gasket defective

Replace gasket

Valve incorrectly seated

Lap valve

Valve stem seized

Replace valve and valve guide

Valve spring weakened

Replace

Cylinder or piston rings worn

Overhaul engine

Piston ring seized

Overhaul engine.

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches

normal operating temperature.

2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the

ignition system.

5. Remove the fuel pump relay from the relay and fuse

box.

6. Engage the starter and check that the cranking speed

is approximately 300 rpm.

7. Install cylinder compression gauge into spark plug

hole.

8. With the throttle valve opened fully, keep the starter

engaged until the compression gage needle reaches
the maximum level. Note the reading.

9. Repeat the test with each cylinder.

The pressure difference between the individual
cylinders should not exceed 100 kPa (14.5 psi).