Campaign - Timing Belt Replacement
BULLETIN NUMBER:SBO1-01-SOO1
ISSUE DATE:
JUNE 2001
GROUP:
ENGINE
2.2L HEC ENGINE - TIMING BELT REPLACEMENT
SERVICE CAMPAIGN 01I-002
CAMPAIGN IDENTIFICATION NUMBER
Number 01I-002 has been assigned to this campaign. This number Will appear on all communications and documentation of any nature dealing with the campaign.
AFFECTED VEHICLES
1998 - 2000 Rodeo (UE) and Amigo (UA) models with 2.2L 4cyl engine
SERVICE INFORMATION
CONDITION
The Timing Belt may fail before the recommended scheduled maintenance. Reported complaints are engine cranks but will not start or stalls while driving and will not restart.
POSSIBLE CAUSE
The Timing Belt core wire deterioration may be accelerated because the seal-ability between the water pump and belt cover was inadequate.
CORRECTION
Follow the special service procedures in this bulletin to replace the timing belt. The accompanying training video "2.2L HEC Engine: Timing Belt Hot Setting Training Video" must be viewed prior to performing the special procedures in this bulletin.
IMPORTANT:
Due to the special procedures involved in this bulletin, a NON COLOR BLIND technician MUST perform the special repair procedures.
DEALER RESPONSIBILITY
Isuzu dealers must service all affected vehicles at no charge to the owner, regardless of mileage, age of vehicle, or ownership.
Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory or arrives at a dealership for service, the dealer must take the necessary steps to ensure that this campaign correction has been made before selling or releasing the vehicle.
All unsold new vehicles in dealer's possession and subject to this campaign must be held and repaired per the service procedure in this Campaign Bulletin before customers take possession of their vehicles.
OWNER NOTIFICATION
American Isuzu Motors Inc. (AIMI) Will send a notification letter to owners of affected vehicles already retailed (See Enclosed Copy). Dealers should follow up with vehicle owners by sending a Campaign Reminder Notice (AIMI SVCF-1052) to all vehicle owners listed in the AIMI Campaign Report AWS 123-1A. Dealers may obtain these postcards from their Regional Office.
SERVICE PROCEDURE
1. Park and secure the vehicle.
2. Open the hood and install the prop rod.
3. Remove the accessory drive belt. (Figure 1)
4. Remove the harness cover. (Figure 1)
5. Remove four (10x) Torx bolts securing the harmonic balancer. Remove the harmonic balancer. (Figure 2)
6. Remove the timing belt cover bolts to remove the timing belt cover. (Figure 2)
7. Rotate the crankshaft in a clockwise direction to Top Dead Center (TDC - Cylinder # 1). (Figure 3 and 4)
8. Insert the cam locking tool (J-43037). (Figure 5)
9. Remove the timing belt tensioner. (Figure 4)
10. Remove the timing belt and discard. (Figure 4)
11. Inspect both left and right idler pulleys. Spin each idler pulley by hand. Replace the idler pulley if it is excessively noisy, or has excessive residue build up on its contact surface. (Figure 6)
12. Clean the block surface thoroughly with sand paper and brake cleaner. (Figure 7)
NOTE:
Brake cleaner or equivalent can be used to remove any dirt, and/or grease from the surface. See diagram for the exact location.
IMPORTANT:
The surface area must be clean prior to applying the thermal sticker.
13. Apply thermal sticker onto the left side of the rear cover hole, with minimal coverage on the threaded hole. (Figure 7)
IMPORTANT:
Thermal sticker must be completely applied on the metal surface only preferably on the left side. Do not cover the bolt hole.
NOTE:
If the engine is fitted with the old style tensioner, you must replace with the new style tensioner. The old style tensioner will have a single V-notch. (Figure 8)
14. Apply the 65°C setting sticker on the new style tensioner. (Figure 8)
NOTE:
The 65cC sticker must be aligned to the top and right sides of both the sticker surfaces and the tensioner backing plate. (Figure 8)
15. Install the timing belt tensioner, and tighten the timing belt tensioner bolt by hand. (Figure 9)
IMPORTANT:
Ensure that the timing belt tensioner locating lug is correctly positioned on the oil pump. (Figure 9)
16. Rotate the adjustment arm clockwise to the 7 o'clock position. (Figure 9)
17. Install the new timing belt (P/N HEC 2-90000-915-0) in the following order - crank, tensioner, water pump, left idler, cam gears, right side idler. (Figure 10)
18. Take up slack by applying a light clockwise force to the crankshaft. Check the crank timing mark. (Figures 3 and 5)
19. Use the 6 mm alien key to rotate in the counter clockwise direction and hold the adjustment arm to set the pointer at approximately midway position of the tensioner backing plate. (Figure 11)
NOTE:
The tensioner pointer must be mid-way between the setting window and the left hand edge of the sticker.
IMPORTANT:
The adjustment arm should rest close between the 4 o'clock and 5 o'clock position. This ensures proper spring tension in the tensioner.
20. while still maintaining the tension on the adjustment arm, tighten the tensioner mounting bolt to the specified torque of 11 lb ft (15 N.m). (Figure 11)
21. Check if the 70°C indicator is blue. If the indicator is blue, allow the vehicle to cool until the 60°C indicator is green, brown, or black. (Figure 12)
22. Remove the cam locking tool. (Figure 5)
23. Start the engine and heat until the 65°C is green. (Figure 12)
CAUTION:
Do not rev the engine. The timing belt may jump and cause personal injuries.
24. Watch the sticker for any color change. The 60°C indicator will turn brown then green, followed by the 65°C indicator. Turn off the engine once the 65°C indicator has changed from brown to green. (Figure 12)
NOTE:
The engine must be turned off before the 70°C indicator turns brown. Ensure the 65°C indicator is green.
25. Rotate the crankshaft clockwise by hand to TDC Cylinder # 1. (Figure 5)
CAUTION:
Do not turn the engine counter clockwise or damage may occur. The Final Tensioner Setting must be done at 65°C.
26. Insert the cam locking tool. (Figure 5)
27. Take up slack by applying a light clockwise force to the crankshaft. Check the crank timing mark. (Figures 3 and 5)
28. Install the 6 mm alien wrench to the adjustment arm and apply some tension, loosen the tensioner bolt just enough to allow movement of the adjustment arm. Move the adjustment arm counter clockwise until the pointer is at the right edge of the backing plate. Then move the adjustment arm in a clockwise direction until the pointer is on the right edge of the setting window at 65°C. (Figures 13 and 14)
IMPORTANT:
The pointer must always approach the setting position from the right. If the pointer is moved beyond the setting window, the Final Tensioner Setting Procedure must be redone.
29. while holding the adjustment arm securely with the allen wrench, tighten the 13 mm tensioner bolt and torque to 15 lb ft (20 N.m). If movement occurs, the Final Tensioner Setting procedure must be redone. (Figure 14)
30. Remove the cam locking tool.
THE GOLDEN RULE
31. Start the engine and let it idle.
32. Check that the 65°C indicator is green and that the tensioner pointer is operating in the setting window, then turn off the engine. If the 65°C indicator is brown or black, let the engine idle until the 65CC indicator is green. If the pointer is outside the setting window, then repeat the Final Tensioner Setting procedure. (Figures 13, 14 and 15)
33. Install the timing belt cover clip on to the timing belt cover. Pull the timing belt cover seal to install the clip, then reinstall the timing belt seal. (Figure 16)
IMPORTANT:
The pre-molded timing belt clip must still be present on the timing belt cover. The timing belt cover will need to be replaced if the clip is damaged.
34. For vehicles with engine serial numbers on or before X22SE25005567, you must perform Steps 36 and 37. For vehicle with engine serial numbers between X22SE25005567 up to and including X22SE25052624, perform Steps 35, 36, and 37. Engine serial numbers after X22SE25052624 proceed to Step 38.
35. Inspect the two backing plate retaining bolts. If the bolts are secured, proceed to Step 38. If the bolts are loose proceed to Step 36.
36. Remove loose backing plate retaining bolts behind the cam gears. (Figure 17)
37. Apply medium strength thread locking compound on the bolts and reinstall. Tighten the backing plate retaining bolts to the specified torque of 4.4 lb ft. (Figure 17)
38. Install the timing belt cover. Torque the bolts to 4.4 lb ft (6 N.m). (Figure 21)
39. Install the harmonic balancer. Torque the bolts to 14 lb ft (20 N.m). (Figure 21)
40. Remove the alternator mounting bolts and swing away to obtain access to the water pump for the next step. (Figure 19)
41. Apply Permatex # 16 (Black Silicone Adhesive Sealant) or equivalent to the rear timing belt cover water pump lug. (Figure 20)
42. Reposition the alternator and tighten the long bolts to 26 lb ft (35 N.m) and the short bolts to 15 lb ft (20 N.m).
43. Install the engine harness cover.
Torque the bolts to 4.4 lb ft (6 N.m).
(Figure 1)
44. Install the accessory belt. (Figure 1)
45. Fill out the "Installation Label" with the Timing Belt part number (P/N 2-90000-915-0), Vehicle Mileage and Date. Attach the Installation Label on the top of the valve cover.
46. Start the engine and inspect engine operation. Close the hood and return the vehicle to the customer.
APPLYING THE CAMPAIGN LABEL
1. Using a ball-point pen, fill out the following information on a campaign label (Part Number: 2-90028-700-0)
^ This campaign number: O1I-002
^ Dealer Code
^ Repair Date: (Month/Day/Year)
2. Affix the campaign label adjacent to the manufacturer's identification label located on the driver's side B-pillar.
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
Use the new labor operation shown.
WARRANTY CLAIM SUBMISSION INFORMATION
For your convenience, please use this information when submitting your warranty claim.