1998 Isuzu Amigo. 2.2L DOHC 4-CYL 1998 ENGINES Isuzu - 2.2L DOHC 4-Cylinder ENGINES Isuzu - 2.2L DOHC 4-Cylinder

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1 ENGINE IDENTIFICATION 2.2L DOHC 4-CYL 1998 ENGINES Isuzu - 2.2L DOHC 4-Cylinder NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION. ENGINE IDENTIFICATION CODES Engine Vin Code 2.2L DOHC D ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Hydraulic lash adjusters are used. Valve clearance adjustment is not necessary. REMOVAL & INSTALLATION NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal. FUEL PRESSURE RELEASE Disconnect negative battery cable. Loosen fuel filler cap to release tank pressure. Remove fuel pump fuse. Reconnect negative battery cable. Start engine and run until it stalls. Crank engine for an additional 3 seconds to release remaining fuel pressure. Disconnect negative battery cable. Reinstall fuel pump fuse. Some residual fuel pressure may exist. Cover fuel lines with shop towel before disconnecting. VALVE COVER Removal Disconnect negative battery cable. Remove air intake duct and bracket. Disconnect PCV hose from valve cover. Disconnect any electrical connectors interfering with valve cover removal. Disconnect spark plug wires from spark plugs. Remove accessory drive belt. Remove crankshaft pulley. Remove timing belt cover. Loosen timing belt rear cover bolts and remove camshaft angle sensor. Remove 10 valve cover bolts and remove valve cover. Installation Install camshaft angle sensor. Tighten timing belt rear cover bolts to specification. See TORQUE SPECIFICATIONS. Install valve cover. Tighten bolts to specification. To complete installation, reverse removal procedure. miércoles, 21 de noviembre de :06:27 11:06:34 p.m. Page Mitchell Repair Information Company, LLC.

2 ENGINE Removal 1. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Remove battery. Remove hood. Drain engine coolant. Remove throttle cable and air intake duct/air cleaner cover assembly. Disconnect 3 engine wire harness connectors on left rear of engine compartment. 2. Disconnect brake booster vacuum hose. Disconnect radiator fan wire connector. Disconnect ground wire connectors from sides of engine compartment. Remove transmission. See REMOVAL & INSTALLATION article in TRANSMISSION SERVICING for A/T, or see appropriate article in CLUTCHES for M/T. Remove power steering pump with hoses attached and set aside. 3. Disconnect 2 chassis wire harness connectors from right rear of engine compartment (under fuse box). Remove engine ground cable from frame. Remove lower radiator hose. Remove heater hoses. Remove front grille. Remove wire harness clip located behind right horn. Remove engine mount-to-frame bolts. Remove engine assembly. Installation To install, reverse removal procedure. Ensure transmission locating dowels are installed in correct positions on engine. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust throttle cable free play, if necessary. Throttle cable free play should be " ( mm). Fill radiator with coolant. Inspect fuel system for leaks. INTAKE MANIFOLD Removal 1. Release fuel pressure. see FUEL PRESSURE RELEASE. Disconnect negative battery cable. Remove air intake duct/air cleaner cover assembly. Drain engine coolant. Remove coolant hoses from throttle body. Disconnect sensor wire connectors from throttle body. 2. Disconnect fuel supply line and return hose from fuel rail. Disconnect fuel injector wiring. Remove fuel rail. Disconnect throttle cable from throttle body. Remove generator upper brackets. Remove coolant pipe. Remove intake manifold support bracket. Remove ignition coil bracket. Remove intake manifold mounting bolt and 7 mounting nuts. Remove intake manifold. Installation To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Fill radiator with coolant. Inspect fuel system for leaks. EXHAUST MANIFOLD Removal Disconnect negative battery cable. Remove air intake duct/air cleaner cover assembly. Remove air intake duct bracket and ground cable. Remove exhaust manifold heat shield. Remove front exhaust pipe-to-manifold nuts. Remove exhaust manifold mounting nuts. Remove exhaust manifold. miércoles, 21 de noviembre de :06:27 p.m. Page Mitchell Repair Information Company, LLC.

3 Installation To install, reverse removal procedure. Tighten exhaust manifold mounting nuts in 3 steps to specification in sequence. See Fig. 1. See TORQUE SPECIFICATIONS. Fig. 1: Exhaust Manifold Tightening Sequence CYLINDER HEAD Removal 1. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Remove air intake duct/air cleaner cover assembly. Drain engine coolant. Remove upper radiator hose. Disconnect exhaust pipe from manifold. Disconnect heater hoses from engine. Remove throttle body coolant hose. 2. Disconnect fuel supply hose from fuel rail. Disconnect EVAP canister hose and purge valve wire connector. Remove intake manifold support bracket. Remove engine wire harness cover. Disconnect 3 miércoles, 21 de noviembre de :06:27 p.m. Page Mitchell Repair Information Company, LLC.

4 chassis wire harness connectors from left rear of engine compartment. 3. Disconnect power steering pressure switch wire connector. Remove timing belt. See TIMING BELT. Disconnect spark plug wires from spark plugs. Disconnect camshaft angle sensor wire connector. Remove valve cover. See VALVE COVER. Remove both timing belt idler pulleys. Remove timing belt rear cover. Remove camshaft angle sensor. 4. Disconnect oil pressure switch wire connector. Remove camshafts. See CAMSHAFTS. Using Cylinder Head Socket (J-42623), remove cylinder head bolts in reverse order of tightening sequence. See Fig. 2. Remove cylinder head. See Fig. 3. Inspection Check cylinder head for warpage. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Surface or replace cylinder head if warpage is not within specifications. Check cylinder head height. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace cylinder head if height is not within specification. Fig. 2: Cylinder Head Bolt Tightening Sequence miércoles, 21 de noviembre de :06:27 p.m. Page Mitchell Repair Information Company, LLC.

5 Fig. 3: Exploded View Of Cylinder Head Installation Install NEW cylinder head gasket on cylinder block. Install cylinder head. Tighten NEW cylinder head bolts in sequence to specification. See Fig. 2. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. CRANKSHAFT FRONT SEAL Removal & Installation Remove timing belt. See TIMING BELT. Remove timing belt drive pulley. Remove crankshaft front seal using seal puller. Lubricate seal lip with engine oil. Using Seal Installer (J-39202), install crankshaft front seal. To complete installation, reverse removal procedure. TIMING BELT miércoles, 21 de noviembre de :06:27 p.m. Page Mitchell Repair Information Company, LLC.

6 Removal Disconnect negative battery cable. Remove accessory drive belt. Remove engine wire harness cover located at left rear of engine compartment. Disconnect 3 wire harness connectors. Remove crankshaft pulley. Disconnect 3 chassis wire harness connectors from left rear of engine compartment. Remove engine wire harness cover from front of engine. Remove timing belt cover. If timing belt is to be reused, mark direction of rotation for installation reference. Remove timing belt tensioner. Remove timing belt. Installation 1. Install timing belt tensioner and temporarily tighten mounting bolt. Ensure timing marks are aligned. Insert Camshaft Locking Tool (J-43037) between intake and exhaust camshaft sprockets to prevent camshaft sprockets from moving. See Fig. 4. Ensure tension side of timing belt is tight. Rotate timing belt tensioner clockwise to tighten belt. 2. For new timing belt, pointer on tensioner should be aligned with center of "V" notch. See Fig. 5. For used timing belt, pointer will be about 0.16" (4.0 mm) from center of "V" notch. See Fig. 5. Tighten tensioner bolt. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. miércoles, 21 de noviembre de :06:27 p.m. Page Mitchell Repair Information Company, LLC.

7 Fig. 4: Aligning Timing Marks miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

8 Fig. 5: Tightening Timing Belt CAMSHAFT miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

9 Removal Disconnect negative battery cable. Remove valve cover. See VALVE COVER. Remove timing belt. See TIMING BELT. Hold camshafts using adjustable wrench on hexagonal portion of camshafts. Remove camshaft sprockets. Remove camshaft bearing cap bolts and remove camshafts. Installation 1. Ensure camshaft journals and hydraulic lash adjusters are clean. Lubricate camshaft journals and hydraulic lash adjusters with engine oil. Install camshafts. Install camshaft bearing caps in their original locations. Intake camshaft bearing caps are numbered from 1 to 5, front to rear. Exhaust camshaft bearing caps are numbered from 6 to 10, front to rear. Apply sealer to mounting surfaces of camshaft bearing cap No. 1, 5, 6 and Tighten camshaft bearing cap bolts in sequence to specification. See Fig. 6. See TORQUE SPECIFICATIONS. Using Camshaft Seal Installer (J-42609), install camshaft seals. Install camshaft sprockets. Ensure camshaft sprockets are installed in their correct locations. Ensure timing marks are aligned. See Fig. 7. To complete installation, reverse removal procedure. Fig. 6: Camshaft Bearing Cap Tightening Sequence miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

10 Fig. 7: Installing Camshaft Sprockets CRANKSHAFT REAR OIL SEAL Removal Remove transmission. See REMOVAL & INSTALLATION article in TRANSMISSION SERVICING for A/T, or appropriate article in CLUTCHES for M/T. Using Flywheel Holder (J-42618), remove flywheel bolts. Remove flywheel. Remove crankshaft seal. Installation miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

11 Lubricate seal ring lip with grease. Using Seal Ring Installer (J-42613) and Crankshaft Seal Installer (J-42616), install seal ring and seal. To complete installation, reverse removal procedure. WATER PUMP Removal & Installation 1. Remove timing belt. See TIMING BELT. Drain engine coolant. Remove lower radiator hose. Remove water pump. Lubricate NEW "O" ring with silicone grease. Install water pump. Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Fill engine with coolant. OIL PAN Removal & Installation Drain engine oil. Remove oil pan bolts. It may be necessary to raise engine for clearance. Remove oil pan. To install, clean sealing surfaces. Apply a bead of silicone sealer to oil pan sealing surface. Install oil pan within 5 minutes. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Fill engine with oil. OVERHAUL CYLINDER HEAD Cylinder Head Measure camshaft bearing oil clearance. See CAMSHAFT table under ENGINE SPECIFICATIONS. Replace cylinder head if oil clearance exceeds specification. Measure cylinder head warpage. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Surface cylinder head if warpage exceeds specification. Measure cylinder head height from deck to valve cover sealing surface. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace cylinder head if height is not within specification. NOTE: Manufacturer does not supply valve guide removal and installation procedure. Valve Guides Measure valve guide diameter. Measure valve stem diameter. Difference between measurements is stem-toguide clearance. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace valve and valve guide as a set if stem-to-guide clearance exceeds specification. Valve Seat To remove valve seat, weld a rod to valve seat contact surface. Allow rod to cool. Strike rod with a hammer to remove valve seat. To install, heat cylinder head and cool valve seat. Press valve seat into cylinder head. Valves Measure valve stem-to-guide clearance. If clearance exceeds specification, replace valve and valve guide as a miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

12 set. CYLINDER BLOCK ASSEMBLY Piston & Rod Assembly 1. DO NOT reuse piston pins if piston and rod are disassembled. To remove piston pin, heat connecting rod in hot oil. Remove piston pin with brass drift. Measure piston pin-to-rod clearance. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Replace connecting rod if clearance is not within specification. 2. Insert NEW piston pin into piston. If piston pin does not rotate smoothly, measure piston-to-pin clearance. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. If clearance exceeds specification, replace piston. Install pistons with arrow on top of piston pointing toward front of engine. 3. Inspect pistons for cracks or damage. Replace piston, if necessary. To install piston pin, heat connecting rod enough to install piston pin smoothly. Press piston pin into piston. Fitting Pistons Measure cylinder bore diameter in axial and thrust directions at 6 points in cylinder. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. If any measurement is not within specification, bore cylinder for oversize piston. Piston Rings Measure piston ring end gap and side clearance. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Replace rings or piston as necessary. Install compression rings with end gaps 180 degrees apart. Install oil ring gaps 1-2" ( mm) from end gap of ring No. 2. See Fig. 8. miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

13 Fig. 8: Installing Piston Rings Rod Bearings Inspect rod bearings for damage and excessive wear. Measure rod bearing oil clearance using Plastigage. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. If oil clearance exceeds specification, replace rod bearings as a set. miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

14 Crankshaft & Main Bearings 1. Inspect crankshaft main and rod journals for damage and excessive wear. Measure main bearing oil clearance using Plastigage. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Machine crankshaft and install undersize bearings if clearance exceeds specification. 2. Measure crankshaft runout. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Replace crankshaft if runout exceeds specification. Inspect crankshaft sensor ring for damage. Replace sensor ring if damaged.see Fig. 9. Fig. 9: Exploded View Of Cylinder Block Thrust Bearing Measure crankshaft end play using micrometer installed at rear of crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. If end play exceeds specification, replace thrust bearings as a set. miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

15 Cylinder Block Measure cylinder block deck warpage. If warpage is less than " (0.400 mm), surface cylinder block. Replace cylinder block if warpage exceeds " (0.400 mm). Balancer Unit Adjustment 1. Remove oil pan. See OIL PAN. Remove oil strainer and oil pan support. Remove baffle plate.see Fig. 10. Turn crankshaft clockwise to align timing mark to TDC. See Fig. 4. The flattened side of both balancer shafts must face downward. See Fig. 11. Fig. 10: Exploded View Of Balance Unit & Related Parts miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

16 Fig. 11: Aligning Balance Shafts 2. Install Backlash Checker (J-43038) on balancer shafts as shown. See Fig. 12. Measuring arm must point to 9 o'clock position. Mount dial indicator onto cylinder block. Place probe of dial indicator on flat side of measuring arm. miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

17 Fig. 12: Installing Measuring Device 3. Turn bolt on exhaust side balancer shaft both directions. Note backlash on dial indicator. Standard backlash is " ( mm). 4. Turn crankshaft clockwise 45 degrees so that measuring arm is at 6 o'clock position. Loosen bolt and set measuring arm to 9 o'clock position as shown. See Fig. 12. Repeat measurement. 5. Measurement must be made at 4 positions 90 degrees apart. If any measurement is not within specification, backlash must be adjusted. Backlash is adjusted by selecting correct shim. Code on shim indicates shim thickness. See BALANCER SHIM CODES table. BALANCER SHIM CODES Code Thickness In. (mm) ( ) ( ) miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

18 ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) 6. Remove balancer unit and shim. See Fig. 10. Check code on balancer shim. The next larger or smaller balancer shim code alters backlash by " (0.020 mm). Use BALANCER SHIM CODES table to obtain correct shim. 7. To install, ensure crankshaft TDC mark is aligned. See Fig. 4. Ensure Flattened sides of balancer shafts are pointed downward. See Fig. 11. Install correct balancer shim and balancer unit. 8. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Fill engine with oil. ENGINE OILING ENGINE LUBRICATION SYSTEM A gear-type oil pump is driven by front of crankshaft. Oil pump supplies pressurized oil through a full-flow oil filter, to main oil gallery in cylinder block. Oil for camshaft bearings and hydraulic valve lash adjusters are supplied through cylinder head oil gallery. Vent valves allow air to be expelled from oil in cylinder head.see Fig. 13. miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

19 Fig. 13: Diagram Of Engine Oil Circuit Crankcase Capacity Oil capacity is 4.8 qts. (4.5L) with filter. Oil Pressure With engine temperature at 176 F (80 C), ensure oil pressure is 21.8 psi (15 kg/cm 2 ) at idle. OIL PUMP Removal & Disassembly Remove timing belt. See TIMING BELT. Remove timing belt drive pulley. Remove oil pan. See OIL PAN. Remove oil strainer. Remove oil pan support. Remove oil pump, sleeve and gasket. Inspection Measure rotor to housing side clearance. Standard clearance is " ( mm). If clearance is not within specification, replace oil pump assembly. miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

20 Reassembly & Installation To reassemble, reverse disassembly procedure. Lubricate components with engine oil. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Balance Unit Bolts Step 1 15 (20) Step 2 45 Degrees Camshaft Sprocket Bolt Step 1 36 (49) Step 2 60 Degrees Step 3 15 Degrees Connecting Rod Cap Nuts Step 1 25 (34) Step 2 45 Degrees Step 3 15 Degrees Crankshaft Pulley Bolts 15 (20) Cylinder Head Bolt Step 1 18 (24) Step 2 90 Degrees Step 3 90 Degrees Step 4 90 Degrees Engine Mount Nut 65 (88) Engine Mount-To-Cylinder Block Bolts 36(49) Engine Mount-To-Frame Bolts 30 (41) Engine-To-Transmission Bolts - Exhaust Manifold Nuts 16 (22) Exhaust Pipe Bolts 50 (68) Exhaust Pipe Nuts 18 (24) Flywheel Bolts Step 1 48 (65) Step 2 30 Degrees Step 3 15 Degrees Fuel Line Bracket 18 (24) Generator Bracket Long Bolt 25 (34) Generator Bracket Short Bolt 14 (20) Intake Manifold Bolts/Nuts 16 (22) Intake Manifold Bracket Bolt 16 (22) miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

21 Main Bearing Cap Nuts Step 1 36 (49) Step 2 45 Degrees Step 3 15 Degrees Oil Pan Support Bolts 15 (20) Oil Pressure Switch 37 (50) PCV Hose Flange 18 (24) Timing Belt Idler Bolt 18 (24) Timing Belt Drive Pulley Bolt Step 1 94 (127) Step 2 45 Degrees Transmission Mount Bolts 23 (31) Transmission Mount Nuts 36 (49) Water Outlet Bolts 11 (15) Water Pump Bolts 18 (24) INCH Lbs. (N.m) Air Intake Duct Bolt 62 (7) Air Intake Duct Clamp 27 (3) Camshaft Bearing Cap Bolts 53 (6) Camshaft Position Sensor Bolts 71 (8) Crankshaft Sensor Ring 115 (13) Exhaust Manifold Cover Bolts 71 (8) Oil Pan Bolts Step 1 71 (8) Step 2 30 Degrees Oil Pump Mounting Bolts 53 (6) Oil Strainer Bolts 71 (8) Spark Plug Wire Cover 27 (3) Throttle Body Nuts 80 (9) Timing Belt Cover Bolts 53 (6) Valve Cover Bolts 71 (8) ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Application Specification Displacement 134 Cu. In. (2.2L) Bore 3.39" (86.0 mm) Stroke 3.72" (94.6 mm) Compression Ratio 9.6:1 Fuel System SFI miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

22 RPM 5200 Torque Ft, RPM 4000 CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS Application In. (mm) Crankshaft End Play Standard ( ) Wear Limit.0118 (.210) Maximum Runout.0012 (.030) Main Bearings Journal Diameter Standard Size White ( ) Green ( ) Brown ( ).010" (.25 mm) Undersize Green/Blue ( ) Brown/Blue ( ).020" (.50 mm) Undersize Green/White ( ) Brown/White ( ) Oil Clearance Standard ( ) Wear Limit.0047 (.120) Connecting Rod Bearings Journal Diameter Standard Size No Color ( ).010" (.25 mm) Undersize Blue ( ).020" (.50 mm) Undersize White ( miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

23 48.488) Oil Clearance Standard ( ) Wear Limit.0047 (.120) Journal Width ( ) CONNECTING RODS CONNECTING RODS Application In. (mm) Connecting Rod Big End Width ( ) PISTONS, PINS & RINGS PISTONS, PINS & RINGS Application In. (mm) Pins Piston Pin-To-Rod Interference Fit ( ) Piston Pin-To-Piston Clearance ( ) Rings End Gap No. 1 & ( ) No. 3 (Oil) ( ) Side Clearance ( ) CYLINDER BLOCK CYLINDER BLOCK Application In. (mm) Cylinder Bore Diameter Grade ( ) Grade ( ) Rebore Size.020 (.50) Maximum Deck Warpage.008 (.20) Maximum Repairable Warpage.016 (.40) CYLINDER HEAD CYLINDER HEAD Application Height Specification 5.276" ( mm) miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

24 Valve Seat Width Intake Exhaust Valve Stem-To-Guide Clearance Intake Exhaust " ( mm) " ( mm) " ( mm) " ( mm) miércoles, 21 de noviembre de :06:28 p.m. Page Mitchell Repair Information Company, LLC.

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