2.

2L 4-CYL DIESEL - VIN [S]

1986 Isuzu Trooper II

1986 ISUZU ENGINES

2.2L 4-Cylinder Diesel

P’UP, Trooper II

* PLEASE READ THIS FIRST *

NOTE: For engine repair procedures not covered in this article,
see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article
in the GENERAL INFORMATION section.

ENGINE CODING

ENGINE IDENTIFICATION
Engine identification code is 8th character of the Vehicle
Identification Number (VIN). The VIN is stamped on a metal tab,
located on top of instrument panel near lower left of windshield.
Engine serial number is stamped on a machined pad, located at front
of engine block.

ENGINE IDENTIFICATION CODE TABLE

Application VIN Code

2.2L 4-Cylinder Diesel

P’UP & Trooper II ......................... S

ENGINE, MANIFOLDS & CYLINDER HEAD

ENGINE
Removal (P’UP)
1) Remove hood. Disconnect battery cables and remove
battery. Remove lower engine cover. Drain coolant, crankcase and
transmission. Remove air cleaner assembly. Remove radiator hoses and
drive belts.
2) Remove fan, fan shroud, radiator grille and radiator.
Disconnect accelerator control cable. Disconnect A/C compressor
control cable (if equipped). Disconnect fuel hoses from injection
pump.
3) Disconnect transmission wiring. Disconnect vacuum hose at
fast idle actuator and wiring at fuel cut solenoid. Disconnect
sensing resistor, thermoswitch and A/C compressor switch wiring.
4) Disconnect heater hoses. Disconnect vacuum hoses from
vacuum pump. Disconnect alternator wiring. Disconnect exhaust pipe
from manifold and remove mounting bracket from engine backing plate.
Disconnect wiring from starter.
5) On 2WD models, remove transmission gearshift lever.
Disconnect speedometer and ground cables from transmission.
Disconnect drive shaft at differential and remove shaft.
6) Remove return spring and clutch cable from clutch release
lever. Remove cable through stiffener bracket. Remove rear
transmission mount bolts. Attach engine hoist. Raise engine and
transmission. Remove rear crossmember.
7) Remove transmission rear extension mounting nuts. Remove
engine mounting bolt and nuts. Ensure that engine and transmission
are completely disconnected. Pull engine forward. Remove engine and
transmission as an assembly.
8) On 4WD models, remove return spring from transfer
gearshift lever. Remove transmission and transfer gearshift levers.
Remove transmission gearshift lever quadrant. Remove starter.
9) Disconnect speedometer cable. Disconnect rear drive
shaft at differential. Disconnect drive shaft center bearing and
remove rear drive shaft. Remove front drive shaft. Disconnect
clutch cable. Remove flywheel cover and transfer case. Remove rear
transmission mounting bolts.
10) Support transmission. Remove rear crossmember. Support
engine. Remove transmission-to-engine mounting bolts. Turn
transmission 90 degrees clockwise and remove transmission. Ensure
that engine is completely disconnected. Pull engine forward.
Carefully remove engine.

Removal (Trooper II)

1) Disconnect battery ground cable. Remove engine hood.
Remove battery assembly. Remove splash cover. Drain cooling system by
opening drain plugs on radiator and on cylinder block. Disconnect air
cleaner connecting hose.
2) Disconnect upper water hose at engine side. Loosen
compressor drive belts by moving power steering oil pump or idler (if
equipped). Remove cooling fan and fan shroud. Disconnect lower water
hose at engine side. Remove radiator grill. Remove radiator attaching
bolts. Remove radiator.
3) Disconnect accelerator control cable from injection pump
side. Disconnect air conditioning compressor control cable (if
equipped). Disconnect fuel hoses from injection pump. Disconnect
battery cable from body. Disconnect transmission wiring. Disconnect
vacuum hose from fast idle actuator.
4) Disconnect connector at fuel cut solenoid. Disconnect
sensing resistor, thermoswitch, and A/C compressor switch connectors.
Disconnect heater hoses extending from heater unit on dash panel
side. Disconnect vacuum hose at master-vac. Disconnect vacuum hose
from vacuum pump. Disconnect generator wiring at connector.
5) Disconnect exhaust pipe mounting brake from engine
backing plate. Disconnect starter motor wiring. Disconnect battery
cable from starter motor. Slide transmission and transfer gearshift
lever boot upwards on each lever, remove gearshift lever attaching
bolts. Remove return spring from transfer gear shift lever and remove
levers.
6) Remove transmission. Remove engine mounting bolts and
nuts. Ensure that engine is slightly raised before removing engine
mounting bolts and nuts. Install engine lift hangers on front and
rear. Ensure that all parts have been removed or disconnected from
engine that are fastened to frame side. Move engine toward front of
vehicle by maneuvering hoist. When front part of engine is raised
slightly above horizontal, remove engine.

Installation
Replace engine mounts showing signs of deterioration,
separation or unusual wear. Reverse removal procedure to complete
installation. On 4WD models, install transfer gearshift lever with
transfer case in "2H" position. Check fluid levels. Adjust clutch.

MANIFOLDS
Removal
Remove air cleaner assembly. Disconnect exhaust pipe from
exhaust manifold. Remove intake and exhaust manifolds. Remove
manifold gasket.
 Installation
Install intake/exhaust manifold gasket with mark turned up
and pointing outward. Reverse removal procedure to complete
installation.

CYLINDER HEAD
Removal
1) Remove lower engine cover. Drain cooling system. Remove
intake and exhaust manifolds. Disconnect upper radiator hose from
engine. Remove fan and fan shroud.
2) Disconnect injection pipes. Remove nozzle holder nozzle
holder assembly. Remove valve cover. Starting with outer bolts and
working inward, loosen rocker arm shaft brackets.

Fig. 1: Cylinder Head Tightening Sequence

Courtesy of Isuzu Motor Co.

3) Remove rocker arm shaft assembly. Remove push rods.

Remove joint bolt and disconnect leak-off pipe. Loosen head bolts in
reverse order of tightening sequence. Remove cylinder head and gasket.

Installation
Install head gasket with "TOP" mark facing up. Install and
tighten cylinder head. See Fig. 1. Install push rods and rocker arm
shaft assembly. See Fig. 2. Reverse removal procedure to complete
installation.
Fig. 2: Rocker Arm Shaft Assembly Tightening Sequence
Courtesy of Isuzu Motor Co.

CAMSHAFT

TIMING BELT COVERS

Removal & Installation
Remove lower engine cover. Drain cooling system. Remove
battery. Remove fan, fan shroud, top radiator hose and drive belts.
Remove 4 crankshaft pulley bolts and crankshaft pulley. Remove timing
belt covers. To install, reverse removal procedure.

TIMING BELT & VALVE TIMING

Removal
1) Remove timing belt covers. Position No. 1 cylinder at TDC
of compression stroke. Ensure injection pump and camshaft sprocket
timing marks are aligned. See Fig. 3.
2) Remove injection pump pulley flange bolts and remove
flange. Remove tensioner spring without using excess force on spring.
Remove tension pulley nut and tensioner assembly. Remove timing belt.
Fig. 3: Timing Belt Sprocket Alignment
Courtesy of Isuzu Motor Co.

Installation
1) Ensure that timing marks on injection pump, camshaft
sprockets, crankshaft pulley and timing pointer are aligned. See
Fig. 4. Install timing belt over crankshaft sprocket, camshaft
sprocket and injection pump sprocket.

Fig. 4: Timing Mark Alignment

Heavy Black arrows show points of timing mark alignment. Courtesy of
Isuzu Motor Co.
 2) Install tensioner assembly so that end of tensioner is in
contact with 2 pins on timing pulley housing. See Fig. 5. Hand
tighten nut. Install tension spring. Tighten nut to 22-36 ft. lbs.
(30-49 N.m).
3) Turn crankshaft 2 complete revolutions in normal
direction of rotation, then turn crankshaft 90 degrees past TDC.
Loosen tensioner nut completely and allow tensioner to take up slack.
Tighten nut.

Fig. 5: Timing Belt Tensioner Installation

Ensure that end of tensioner is in contact with pins. Courtesy of
Isuzu Motor Co.

4) Install and tighten injection pump pulley flange. Ensure

hole in flange lines up with triangular timing mark on pump sprocket.
See Fig. 3. Turn crankshaft 2 more turns, bringing No. 1 cylinder to
TDC on compression stroke.
5) Check timing mark alignment. Check timing belt tension
with Tension Gauge (J-29771). Tension should be 33-55 lbs. (15-25
kg). Reverse removal procedure to complete installation.

INJECTION PUMP TIMING

1) Ensure that alignment marks on injection pump flange and
injection pump front bracket are aligned. See Fig. 6. Place No. 1
cylinder at TDC of compression stroke.
2) With timing belt cover removed, ensure that timing belt
is properly tensioned and that sprocket timing marks are aligned.
Disconnect injection pipe from pump. Remove distributor head screw.
Fig. 6: Injection Pump Alignment Marks
Ensure that timing marks on pump and bracket are aligned. Courtesy of
Isuzu Motor Co.

3) Install Dial Indicator (J-28827) and set lift to about

.040" (1.0 mm) from plunger. Turn engine until No. 1 cylinder is
45-60 degrees BTDC. Calibrate dial indicator to zero. Turn crankshaft
pulley slightly in both directions and check that gauge indication is
stable.
4) Turn crankshaft in normal direction of rotation until 15
degrees BTDC mark on Federal non-turbo, 13 degrees BTDC mark on
Calif. non-turbo, or 10 degrees mark on turbo models is aligned with
timing pointer. Dial indicator should read .020" (0.5 mm).
5) If indicator reading is not correct, hold crankshaft in
place and loosen nuts on injection pump flange. Move injection pump
until correct reading is obtained. Tighten nuts and recheck reading.

Fig. 7: Injection Pump Timing Adjustment

Courtesy of Isuzu Motor Co.

CAMSHAFT
 Removal
1) Remove engine from vehicle. Remove valve cover, rocker
arm shaft assembly and push rods. Remove lifter cover and rocker oil
feed pipe from side of engine. Remove lifters. Remove timing belt
covers and timing belt.
2) Install a 6.0 mm bolt through hole in camshaft sprocket
and into threaded hole in housing to prevent sprocket from turning.
Remove sprocket bolts. Remove sprocket with Puller (J-22888). Remove
oil seal retainer. Remove camshaft.

Installation
Lubricate camshaft lobes, journals and camshaft bearings
with oil. Carefully install camshaft to avoid damage to bearings.
Reverse removal procedure to complete installation.

CAMSHAFT OIL SEAL

Removal
1) Remove timing belt. Install a 6.0 mm bolt through hole in
camshaft sprocket and into threaded hole in housing to prevent
sprocket from turning.
2) Remove sprocket bolts. Remove sprocket using Puller
(J-22888). Remove oil seal retainer and oil seal.

Installation
Install oil seal into retainer until seated. Reverse removal
procedure to complete installation.

CAMSHAFT BEARINGS
Removal & Installation
Remove and install bearings using Camshaft Bearing Remover
and Installer (J-29764). Ensure that oil holes in bearings are
aligned with those in engine block.

CAMSHAFT END PLAY

1) Remove timing belt covers. Attach a dial indicator to
engine block with indicator point on camshaft sprocket center bolt.
Push camshaft rearward and zero dial indicator.
2) Pry camshaft forward and note end play. Maximum allowable
end play is .008" (.20 mm). If end play exceeds specification,
camshaft oil pump drive gear or oil pump gear is worn and should be
replaced.

VALVES

VALVE ARRANGEMENT
E-I-I-E-E-I-I-E (Front-to-rear).

ROCKER ARM SHAFT ASSEMBLY

Removal
Remove valve cover. Starting with outer bolts and working
inward, loosen rocker arm shaft brackets. Remove rocker arm shaft
assembly. If disassembly is necessary, remove end snap rings and keep
parts in order.

Installation
 To install, reverse removal procedure. Starting with outer
bolts and working inward, tighten attaching bolts evenly. See Fig. 2.

VALVE GUIDE SERVICING

Inspection
Using dial indicator, check valve stem-to-guide clearance.
Position dial indicator point about .400" (10.0 mm) above end of
guide. Rock valve stem back and forth and measure movement. If
movement exceeds .008" (.20 mm), replace valve guide and valve.

Removal
Working from combustion chamber side of cylinder head, drive
out old guide with Driver (J-26512).

Installation
Coat outer surface of guide with engine oil. Working from
top side of head, drive guide into head with Driver (J-26512). Guide
should project from cylinder head .472" (12 mm). Always replace valve
guide and valve as a set.

VALVE STEM OIL SEALS

Removal
Remove rocker arm shaft assembly. Position piston of
cylinder to be serviced on TDC. Using Spring Compressor (J-29760),
compress spring and remove valve locks. Release pressure and remove
spring retainer and springs. Remove valve stem oil seal.

Installation
Apply engine oil to inner face of oil seal and valve stem.
Install oil seal. Install inner and outer springs with Green side
(closed-coil end) toward cylinder head. Reverse removal procedure to
complete installation.

VALVE SEAT INSERTS

Inspection
With valves installed in cylinder head, check depth of valve
head below cylinder head surface. If depth exceeds .080" (2.0 mm),
replace valve seat insert.

Removal
Arc-weld a bead of metal around inner face of seat. Allow
seat to cool a few minutes. Using screwdrivers, pry out valve seat.

Installation
Using arbor press, install new seat. Grind seat to correct
width and angle. Lap valve and seat to complete installation.

VALVE SPRINGS
Removal & Installation
To remove and install valve springs, use procedure outlined
in VALVE STEM OIL SEAL removal and installation.

Inspection
Measure spring for free length and spring tension with a
valve spring tester. Using a flat surface and steel square, check
valve springs for squareness. Take measurement between top of spring
and square, while slowly rotating spring. Out-of-square must not
exceed .040" (1.0 mm). Replace springs that fail tests.
 GLOW PLUGS
Inspection
Measure glow plug depth in cylinder head with straightedge
and feeler gauge. If depth exceeds .0008" (.02 mm), glow plug must be
replaced.

Removal
Using a 1/8 - 3/16" brass drift inserted through injection
nozzle hole, drive out glow plug.

Installation
Install lock ball into groove of glow plug. Align lock ball
with groove in cylinder head and drive plug in. Using bench press and
a piece of metal over plug, press glow plug into position. Grind plug
flush with surface of cylinder head.

VALVE CLEARANCE ADJUSTMENT

Ensure rocker arm shaft brackets are properly tightened. Set
No. 1 cylinder to TDC of compression stroke. Adjust clearance of No.
1 and No. 2 intake valves, and No. 1 and No. 3 exhaust valves. Turn
crankshaft 1 full turn to place No. 4 cylinder to TDC of compression
stroke. Adjust remaining valves.

VALVE CLEARANCE ADJUSTMENTS TABLE

Application In. (mm)

All Valves (Cold) ....................................... .016 (.41)

All Valves (Hot) ........................................ .015 (.37)

PISTONS, PINS & RINGS

OIL PAN
Removal & Installation
Remove engine from vehicle. Remove oil pan bolts. Remove oil
pan. To install, reverse removal procedure.

PISTON AND ROD ASSEMBLY

Removal
1) Remove engine from vehicle. Remove cylinder head. Remove
crankcase and oil pan as an assembly. Remove oil pipe sleeve nut from
engine block. Remove attaching bolts. Remove oil pump with oil pipe
attached.
2) Remove carbon deposits from upper edge of cylinder wall.
Remove rod cap. Push piston/rod assembly out of cylinder block.
Install rod cap on its respective piston/rod assembly.

Installation
1) Lightly oil rings, piston and cylinder wall. Make sure
ring gaps are properly spaced. See Fig. 8. Make sure bearing halves
are properly seated in connecting rod and cap.
2) Install ring compressor and compress rings. Install
piston in cylinder with mark toward front of engine. Install and
tighten rod cap. Reverse removal procedure to complete installation.
Fig. 8: Piston Ring Gap Locations
Courtesy of Isuzu Motor Co.

FITTING PISTONS
1) Measure cylinder bore diameter at 5/8" (16 mm) and 4 1/2"
(114 mm) below engine block surface. Take measurements in-line with
and at 90 degrees to crankshaft centerline. If reading is greater
than 3.512" (89.2 mm), rebore cylinder.
2) Measure piston skirt diameter at 2 1/2" (63.5 mm) from
top of piston and at right angle to piston pin. Subtract piston
reading from cylinder diameter to determine piston-to-cylinder wall
clearance. Clearance should be .0014-.0022" (.036-.056 mm).

PISTON DIAMETER SPECIFICATIONS TABLE

Application In. (mm)

Standard ................................. 3.463-3.464 (87.96-87.99)

.5 mm Oversize ........................... 3.483-3.484 (88.46-88.49)
1 mm Oversize ............................ 3.502-3.503 (88.96-88.99)

FITTING RINGS
1) Position rings into cylinder bore at a point where bore
diameter is smallest. Ring must be square in bore. Measure ring end
gap with a feeler gauge.
2) Remove rings from bore and check ring side clearance.
Ensure rings turn freely in ring grooves. When installing rings on
pistons, ensure that gaps are properly positioned. See Fig. 8.
3) Install rings on piston as follows: Expander ring, oil
ring, 2nd compression ring (grooved), then 1st compression ring.
Install compression rings with "N" mark facing upward.

PISTON PIN REPLACEMENT

Removal
 Place piston/rod assembly in soft-jawed vise. Remove snap
rings from piston. Use a brass rod to drive out piston pin.

Inspection
1) Check connecting rod for distortion and parallelism.
Correct or replace connecting rod if distortion exceeds .008" (.20
mm) or parallelism exceeds .006" (.15 mm) per 3.94" (100.0 mm) of
length.
2) Measure inside diameter of connecting rod bushing and
outside diameter of piston pin. If clearance is greater than .002"
(.05 mm), replace piston pin or bushing. Check interference fit
between piston pin and piston pin bore in piston.
3) Interference fit should be 0.0-.0002" (.004 mm). Measure
piston pin outside diameter at several points around circumference.
If pin diameter is greater than 1.062" (26.97 mm), replace piston pin.

Bushing Replacement
Remove piston pin bushing using press and Piston Pin
Remover/Installer (J-29765). Install bushing on connecting rod and
machine hone to obtain .0003-.0008" (.008-.020 mm) standard clearance.

Installation  
Heat piston to about 176 F (80 C). Assemble rod to piston so
that front mark on piston and "ISUZU" mark on rod are on same side.
Rod cap match marks will be on combustion chamber side of piston. See
Fig. 9. Coat piston pin with oil and install. Install snap rings.

Fig. 9: Positioning Rod to Piston

Note position of markings when installing rod to piston. Courtesy of
Isuzu Motor Co.
 CRANKSHAFT & ROD BEARINGS

MAIN BEARINGS
1) Use Plastigage method to check main bearing clearances.
If clearance is greater than .005" (.12 mm), replace crankshaft
and/or bearings. Crankshaft journals and crankpins cannot be reground.
2) Removed crankshaft from engine. Measure crankshaft
journals and crankpins at front, rear and in 2 directions to check
for wear and taper. If crankshaft journal diameter is less than than
2.358" (59.90 mm), replace crankshaft. If crankpin diameter is less
than 2.083" (52.90 mm), replace crankshaft.
3) Check crankshaft runout, by placing "V" blocks under
crankshaft at No. 1 and No. 5 journals. Position dial indicator point
on No. 3 journal. Slowly turn crankshaft, while noting runout. If
runout exceeds .0024" (.061 mm), replace crankshaft. Standard runout
is .001" (.03 mm) or less.
4) Lubricate main bearings. Install thrust bearing with
grooved thrust face turned outward. Install arch gaskets on No. 1 and
No. 5 bearing caps. Use silicone sealer to hold gasket in place.
Gasket should not project more than .002" (.05 mm) from fitting face
of cap. See Fig. 10.
5) Apply thin coat of silicone sealer to fitting face of No.
1 and No. 5 bearing caps. See Fig. 10. Install bearing caps. Ensure
that No. 1 and No. 5 arch gasket protrusions fit properly.
6) Install bearing cap with "A" mark on rear face in No. 2
position. Tighten caps gradually and in sequence 3, 4, 2, 5 and 1.
Ensure that crankshaft turns freely.

Fig. 10: Arch Gasket & Sealer Installation

Install bearing caps before sealer sets up. Courtesy of Isuzu Motor
Co.

CONNECTING ROD BEARINGS

 Mark connecting rod and cap for cylinder identification.
Remove rod cap. Check bearing clearance using Plastigage. If crankpin
is not worn and clearance is excessive, install new bearings.

THRUST BEARING ALIGNMENT

Move crankshaft fully to one end. Using a feeler gauge,
measure clearance between crankshaft and thrust bearing. If clearance
is greater than .012" (.30 mm), replace thrust bearing.

REAR MAIN BEARING OIL SEAL

Removal
Remove engine from vehicle. Remove pressure plate, disc and
flywheel. Remove rear oil seal.

Installation
Coat seal lip with engine oil. Using Seal Installer
(J-22928), install new seal. Reverse removal procedure to complete
installation.

CRANKSHAFT FRONT OIL SEAL

Removal
Remove camshaft oil seal retainer. Keep crankshaft from
turning and remove crankshaft pulley bolt. Using Puller (J-29752),
remove crankshaft sprocket. Remove front oil seal dust cover. Remove
oil seal.

Installation
Coat seal lip with engine oil. Using Seal Installer
(J-24250), install new oil seal. Install dust cover. Using Pulley
Installer (J-26587), install crankshaft sprocket and pulley. Reverse
removal procedure to complete installation.

ENGINE OILING

ENGINE OILING SYSTEM

A rotor-type oil pump is used in 2WD models. A gear-type oil
pump is used in 4WD models. Oil drawn from crankcase passes through a
strainer, then to oil pump.
Oil is delivered to full-flow oil filter, oil cooler and
main oil gallery. By-pass valves are incorporated into oil filter and
oil cooler.
Main oil gallery supplies oil to lubricate crankshaft and
connecting rod bearings. Oil gallery feeds oil to vacuum pump and
camshaft. From camshaft, oil is routed to feed rocker arm shaft
assembly and upper valve train components.
Oil is fed from oil gallery to oil jet pipe, which sprays
oil from below pistons to lubricate cylinder walls and piston pins.
Oil spray from oil jets aids in piston cooling.

CRANKCASE CAPACITY
Capacity on P’UP is 6.0 quarts (5.7L) with oil filter
replacement; 5.6 quarts (5.3L) without filter replacement. Capacity
on Trooper II is 6.4 quarts (6.0L) with filter and cooler.

NORMAL OIL PRESSURE

 
Normal oil pressure is 50 psi (3.5 kg/cm ).

OIL PUMP
Removal
Remove engine from vehicle. Remove crankcase and oil pan as
an assembly. Remove oil pipe sleeve nut from engine block. Remove
attaching bolts. Remove oil pump with oil pipe attached.

Fig. 11: Oil Pump Assemblies

Thoroughly clean all parts prior to measuring clearances. Courtesy of
Isuzu Motor Co.

Inspection (2WD Models)

1) Disassemble oil pump and clean parts thoroughly. Inspect
for signs of unusual wear or damage. With rotors installed in pump,
place a straightedge over housing. Using a feeler gauge, measure
clearance between rotors and straightedge.
2) If clearance is .006" (.15 mm), replace rotor set (pin,
shaft, inner and outer rotors). Using a feeler gauge, measure
clearance between inner and outer rotors. If clearance is greater
than .0055" (.14 mm), replace rotor set.
3) Using a feeler gauge, measure clearance between outer
rotor and pump housing. If clearance is greater than .008-.011"
(.20-.27 mm), replace pump. Check clearance between rotor shaft and
pump body. If clearance is greater than .008" (.20 mm), replace pump.
 Inspection (4WD Models)
1) Disassemble oil pump and clean parts thoroughly. Inspect
for signs of unusual wear or damage. Using a feeler gauge, check
clearance between pump body inner wall and gear tips. If clearance is
greater than .005-.0055" (.13-.14 mm), replace gear set (drive gear
shaft and pin).
2) With gears installed in pump, place a straightedge over
pump housing. Using a feeler gauge, measure clearance between gears
and straightedge. If clearance is greater than .0016-.0037"
(.041-.094 mm), replace pump.

Installation
Assemble pump. Reverse removal procedure to complete
installation.

ENGINE COOLING

WATER PUMP
Removal
Remove lower engine cover and drain cooling system. Remove
battery, fan, fan shroud and upper radiator hose. Remove drive belts
and fan pulley. Remove water pump retaining bolts and remove pump.

Installation
Install water pump using a new gasket. Reverse removal
procedure to complete installation.

NOTE: For further information on cooling systems, see ENGINE

COOLING section.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE




























































Application Ft. Lbs. (N.m)

Cylinder Head Bolts

Step 1 ................................... 40-47 (54-64)
Step 2
New Bolt ................................ 54-61 (73-83)
Used Bolt ............................... 61-69 (83-94)
Camshaft Sprocket Bolt .................... 72-87 (98-118)
Connecting Rod Nuts ........................ 58-65 (79-88)
Crankshaft Sprocket Bolt ............... 124-151 (168-205)
Engine Rear Plate Bolts .................... 55-67 (75-91)
Flywheel Bolts ........................... 83-90 (113-122)
Main Bearing Cap Nuts .................. 116-130 (157-176)
Manifolds Nuts (Intake & Exhaust) .......... 10-17 (14-23)
Injection Pump Timing Pulley Bolt .......... 42-52 (57-71)
Oil Jet Pipe Bolts ......................... 24-27 (33-37)
Oil Jets ......................................... 22 (30)
Oil Cooler Bolts ........................... 54-61 (73-83)
Rocker Arm Shaft Bolts ..................... 10-17 (14-23)
Timing Belt Tensioner Bolts .............. 79-94 (107-127)

ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS TABLE




























































Application Specifications

Displacement
Cu. In. ........................................... 136.6
Liters .............................................. 2.2
Fuel System .................................... Fuel Inj.
HP @ RPM ....................................... 62 @ 4300
Torque Ft. @ RPM ............................... 96 @ 2000
Compr. Ratio ........................................ 21:1
Bore
In. (mm) ...................................... 3.46 (88)
Stroke
In. (mm) ...................................... 3.62 (92)

VALVE SPECIFICATIONS
VALVE SPECIFICATIONS TABLE




























































Application In.(mm).

2.2L
Intake
Head Diam. ......................................... ...
Face Angle ......................................... 45 
Seat Angle ......................................... 45
Seat Width ....................... .047-.059 (1.20-1.50)
Stem Diameter .................... .310-.315 (7.88-8.00)
Stem Clearance ................. .0015-.0027 (.039-.068)
Valve Lift ......................................... ...
Exhaust
Head Diam. ......................................... ...
Face Angle ......................................... 45 
Seat Angle ......................................... 45
Seat Width ....................... .047-.059 (1.20-1.50)
Stem Diameter .................... .309-.315 (7.85-8.00)
Stem Clearance ................. .0025-.0037 (.064-.093)
Valve Lift ......................................... ...

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS TABLE




























































Application In.(mm).

2.2L
Pistons
Clearance ...................... .0014-.0022 (.036-.056)
Pins
Piston Fit ............................ ( 1) .0002 (.004)
Rod Fit ........................ .0003-.0008 (.008-.020)
Rings
Ring No. 1
End Gap .......................... .008-.016 (.20-.41)
Side Clearance ................... .002-.003 (.05-.07)
Ring No. 2
End Gap .......................... .008-.016 (.20-.41)
Side Clearance ................... .001-.002 (.03-.06)
Oil Ring
 End Gap .......................... .008-.016 (.20-.41)
Side Clearance ............... .0008-.0021 (.020-.054)

(1) - Interference fit.

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS TABLE




























































Application In.(mm).

2.2L
Main Bearings
Journal Diam. ............ 2.3591-2.3594 (59.921-59.929)
Clearance ...................... .0011-.0033 (.028-.085)
Thrust Bearing ................................... No. 3
Crankshaft End Play .................. .0012 Max. (.300)
Connecting Rod Bearings
Journal Diam. ............ 2.0835-2.0839 (52.921-52.931)
Clearance ...................... .0016-.0047 (.040-.120)
Side Play .......................................... ...

VALVE SPRING SPECIFICATIONS

VALVE SPRING SPECIFICATIONS TABLE




























































Applications Specifications

2.2L
Inner
Free Length ................................ 1.89 (47.9)
Pressure Lbs. @ In. (Kg @ mm)
Valve Closed .......... (1) 12-14 @ 1.46 ([email protected])
Valve Open ........................................ ...
Outer
Free Length ................................ 1.86 (47.3)
Pressure Lbs. @ In. (Kg @ mm)
Valve Closed ........ (1) 43-49 @ 1.54 ([email protected])
Valve Open ........................................ ...

(1) - Compressed height as measured in spring tension

tester.

CAMSHAFT SPECIFICATIONS
CAMSHAFT SPECIFICATIONS TABLE




























































Application In.(mm).

2.2L
Journal Diam. ...................... 1.87-1.89 (47.6-48.0)
Clearance .............................. .0047 Max. (.002)
Lobe Lift .................................. 1.597 (40.57)

VALVE TIMING SPECIFICATIONS

VALVE TIMING SPECIFICATIONS TABLE




























































Application Specifications

2.2L
Intake 
Open (BTDC) ........................................ 16 
Close (ABDC) ....................................... 54
Exhaust 
Open (BBDC) ........................................ 56 
Close (ATDC) ....................................... 14