Izuzu Motor x22 Se

MY99 Rodeo Service Manual
6A-1
6: Eng¡ne(X22SEZ.zL)
6A: Enginett/lechan¡cal
(z.zl)
ServicePrecaution
WARNING!THIS
VEHICLEHASA SUPPLEMENTAL
RESTRATNT
SYSTEM(SRS).REFERTO THE
sRs coMPoNENT
ANDwlBlNGLocATtoNvtEw rNoRDERTo DETERnrirue
\í/HerHERyou ARE
PERFORMING SERVICEON OR NEARTHE SRS COMPONENTSOR THE SRSWIRING.WHENYOU
AREPERFORMING SERVICE ON OR NEARTHESRSCOMPONENTS OR THESRSWIRING,REFERTO
THESRSSERVICEINFORMAT¡ON. FAILURETO FOLLOWWARNINGSCOULDRESULTIN-POSSIBLE
AIR BAG DEPLOYMENIPERSONALINJURY,ON OTHERWISEUNNEEDED SRSSYSTEMREPAIRS.
cAuTloN!Always use the correctfastenerin the proper location.Whenyou replacea fastener,

use oNLy
the exact part numberfor that application.ISUZUwilicall out those fastenerst|at requirea replacement
after removal.ISUZUwill also call out the fastenersthat requirethread lockersor threadsealant.
UNLESS
OTHERW¡SE SPEGIFIED, do not use supptementalcoatings(Paints,greases,or other corrosion inhibitors)
on threadedfasteners or fastener ioint interfaces. Generáty, such coatings adversely affect the fastener
torque and the ioint clamping force, and may damagethe fástener. Wheriyou install fasteners,
use the
correcttighteningsequenceand specifications.Followingthese ¡nstruct¡onscan help you
avoid damage
to parts and systems.
GeneralDescription
EngineCleanlinessAnd Care
An automobile engineis a combination of manymachined, honed,polishedand lappedsurfaceswithtolerances
thatare measuredin the thousandths of a millimeter(tenthousandihsof an inch).Áccordingly,whenany internal
enginepartsare serviced,careandcleanfiness are important.Throughout this s'ection,
¡t sñouUbe undárstood
that propercleaninEand protectionof machinedsurfacesand frictionáreasis part of the repairprocedure.This
is
considered standardshoppracticeevenif not specifically stated.
' A liberalcoatingof engineoil shouldbe appliedto all frictionareasduringassemblyto protectand
lubricatethe surfaceson initialoperation.
' Whenevervalvetraincomponents, pistons,pistonrings,connectingrods,rodbearings,and crankshaft
journalbearingsare removedfor service,theyshouldbe retainediñ order.
' At the time of installation,
theyshouldbe installedin the samelocationsand withthe samemating
surfacesas whenremoved.
' Batterycablesshouldbe disconnected beforeany majorworkis performedon the engine.Failureto
disconnect cablesmayresultin damageto wireharnessor otherelectricalparts.
' Thefour cylindersof this engineare identifiedby numbers;cylinders1, 2, a and 4, as countedfrom
crankshaft pulley.
GeneralInformation
on EngineService
Thefollowinginformation on engineserviceshouldbe notedcarefully,as it is importantin preventing
damageand
contributing
to reliableenginepérformance:
' Whenraisingor supporting the enginefor any reason,do not usea jack underthe oil pan. Dueto the
smallclearancebetweenthe oil pan and the oil pumpstrainer,jackiÁgagainstthe oil pan may cause
damageto the oil pickup unit.
' The12-voltelectricalsystemis capableof damagingcircuits.Whenperforming anyworkwhereelectrical
terminalscouldpossiblybe grounded,the groundcableof the batteryshouldbe-disconnected atthe battery.
6A-2 MY99 Rodeo Service Manual
' Any t¡methe intakea¡rduct or air cleaneris removed,the intakeopeningshouldbe covered.Thiswill

protectagainstaccidentalentranceof foreignmaterialintothe cylinderwhichcouldcauseextensive
damagewhenthe eng¡neis started.
CylinderBlock
The cylinderblockis madeof casl iron. The crankshaftis supportedby five bearings.The bearingcap is madeof
nodularcasliron.
CylinderHead
The cylinderheadis madeof aluminumalloycastingwitha sparkplug in the center.
Valve Train
Valvesystemis direct-acting
inverteredbuckettappet.
The valvesclearanceadjustmentare hydraulic.
Hydraulicvalvelashadjustment,no adjustmentnecessary.
IntakeManifold
Theintakemanifold
is madeof aluminum
allov.
ExhaustManifold
Theexhaustmanifold
is madeof highSi-Monodular¡ron.
Pistonsand ConnectingRods
Aluminumpistonsare usedafterselectingthe gradethat meetsthe cylinderborediameter.Eachpistonhastwo
compress¡on ringsand one oil ring. The pistonpin is madeof case-harded
steel.Theconnectingrodsare madeof
cast iron. The connectingrod bearingsare madeof steelbackedwith babbittmetal.
Crankshaftand Bearings
Thecrankshaftis madeol nodularcast iron. Pinsandjournalsaregradedfor correctsizeselectionfor theirbearing.
BalanceShaft
Typeis lanchester(twincounter-rotating
shafts).The balanceshaftsare madeof castiron and gearsare
hardfaced.The housingis madeof cast iron. Backlashadjuslmentmethodis shim-balancer housingto block
(selectivefit).
EngineDiagnosis
Hard Starting
1. Start¡ng
MotorDoesNotTurnOver
TroubleShootingProcedure
Turnon headlightsand starterswitch.
Condition PossibleCause Correction

Headlightsgo out or dim Batteryrun down or undercharged Rechargeor replacebattery
considerably
Terminalspoorlyconnected Cleanbatterypostsandterminals
and connectproperly
MY99 Rodeo Service Manual 6A-:

Startingmotorcoilcircuitshorted Overhaulor replace
Startingmotor defective Overhaulor replace
2. lgnitionTrouble- Start¡ngMotorTurnsOverBut EngineDoesNot Start

SoarkTest
Disconnecta hightensioncablefromany sparkplug. Connectthe sparkplugtesterJ-26792(ST-125),crank
the engine,and checkif a sparkis generatedin the sparkplugtester.Beforecrankingthe engine,makesure
that the sparkplugtesteris properlygrounded.To avoidelectricalshock,do nottouchthe hightensioncable
whilethe engineis running.

Sparkjumpsacrossgap Spark plug defective Clean,adjustsparkgap or replace
lgnitiontiming incorrect Referto lgnitionSystem
Fuel not reachingfuel injector(s) Refer to item 3 (Troublein

or engine fuel system)
Valvetiming incorrect Adjust

Enginelackscompression Referto item 4 (Enginelacks
compression)
No sparkingtakes place lgnitioncoil disconnected Connectproperly
or replace
or broken
ElectroniclgnitionSystem Replace
with module
Poor connectionsin engine Correct

harness
PowertrainControlModulecable Corrector replace

disconnectedor defective
3. Troubleln Fuel System

Startingmotorturnsover Fueltank empty F¡II
andsparkoccursbutengine
does not start.
Watert n fuel system Clean
Fuel filter clogged Replacefilter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuelpumpcircuitopen Corrector replace


Evaporative
Emission Control Corrector replace
Systemcircuitclogged
MultiportFuel lnjection Refer to ElectronicFuel
System faulty Injectionsection
4. EngineLacksCompress¡on

Enginelackscompression Spark plug looselyfitted or spark Tightento specifiedtorque or
plug gasket defective replace gasket
Valve timing incorrect Adjust
Cylinderhead gasketdefective Replace gasket
Valve incorrectlyseated Lap valve
Valve stem seized Replacevalve and valve guide
Valve spring weakened Replace
Cylinderor pistonringsworn Overhaulengine

Piston ring seized Overhaulengine.
EngineCompression
Test Procedure
1. Startand runthe engineuntilthe enginereachesnormaloperatinglemperature.
2. Turnthe engineoff.
3. Removeall the sparkplugs.
4. Removeignitioncoilfuse (15A)and disablethe ignitionsystem.
5. Removethe fuel pumprelayfromthe relayand fuse box
6. Engagethe starterandcheckthat the crankingspeedis approximately 300 rpm.
7. Installcylindercompression
gaugeintosparkplug hole.
8. Withthe throttlevalveopenedfully,keepthe starterengageduntilthe compressiongageneedlereaches
the maximumlevel. Notethe reading.
9. Repeatthe test witheachcylinder.
The pressuredifferencebetweenthe individualcylindersshouldnotex@ed1OOkPa (i4.5 psi).
ou Engine
Rough nqrneldlinq
nq or Enqine
tsnqtnestall¡n
Stalli
Troublein fuel injectionsystem ldle air controlvalve defective Replace
Throttleshuttingoff incomplete Corrector replace

Throttle positionsensor circuit Correct or replace
open or shorted
Fuel injectorcircuitsopen Correct or replace

or shorted
Fuel injectorsdamaged Replace

MY99 Rodeo Service Manual 6A-5

Fuel pump relay defective Replace
ManifoldAbsolute Pressure Correct or replace

Sensor cable disconnected
or broken
ManifoldAbsolutePressure Replace
Sensordefective
Engine CoolantTemperature Correct or replace
Sensor cable disconnected
or broken
EngineCoolantTemperature Replace
Sensordefective
IntakeAir Temperature
sensor Corrector replace
cabledisconnected
or broken
lntakeAir Temperature
sensor Replace
defective
KnockSensor(KS)circuits Correct or replace
open or shorteo
KS defective Replace
KS Modulecircuitsopenor ground Corrector replace

KS Module defective Replace
VehicleSpeed Sensorcircuit Corrector replace

open or shorted
VehicleSpeed Sensor defective Replace

Troublein emissioncontrol PowertrainControlModule Replace
system defective
ExhaustGas Recirculation Replace

Valve faulty
Canisterpurge solenoid Correct

circuit open
Canisterpurge solenoiddefective Replace

EvaporativeEmissionCanister Replace
Purge controlvalve defective
Troublein ignitionsystem Refer to Hard Start

TroubleshootingGuide
Others Enginelackscompression Refer to Hard Start
Valve incorrectlyseated Lap valve
Air CleanerFilterclogged Replacefilterelement

Valve timing incorrect Readjust
ldle air controlvalve broken Replace
Rouqh Enoine
o uqn Enqr Runni
n eH u n n t tl
Enginemisfiresregularly lgnitioncoil layer shorted Replace
Spark plugs fouling Clean or installhottertype plug
Sparkplug(s)insulator
nose Replace
leaking
Fuel injector(s)defective Replace
Enginecontrolmodulefaulty Replace
Engineknocksregularly Sparkplugsrunningtoo hot lnstallcoldertype spark plugs
Powertraincontrolmodulefaulty Replace
Enginelacks power Sparkplugsfouled Clean
Fuel injectorsdefective Replace
ManifoldAbsolutePressure(MAP) Corrector replace

Sensor or ManifoldAbsolute
PressureSensorcircuitdefective
EngineCoolantTemperature Corrector replace

Sensoror EngineCoolant
Temperature
Sensorcircuit
defective
EngineControlModulefaulty Replace
IntakeAirTemperature
Sensoror Corrector replace
Sensor
circuitdefective
ThrottlePositionSensoror Throttle Corrector replace
PositionSensorcircuitdefective
KnockSensoror KnockSensor Corrector replace
circuitsdefective
KnockSensorModuleor Knock Corrector replace
SensorModulecircuitsdefective
Hesitation
Hesitationon acceleration Throttle Position Sensor Replacethrottlevalve assembly

adjustmentincorrect
ThrottlePositionSensorcircuit Corrector replace

openor shorted
Excessiveplay in accelerator Adjustor replace
linkage
ManifoldAbsolutePressure(MAP) Corrector replace

Sensorcircuitopen or shorted
MAP Sensor defective Replace
lntake Air Temperature(lAT) Correct or replace

KnockSensor(KS)Circuit Corrector replace

openor shorted
KS Modulecircuitsopenor shorted Corrector replace
IAT Sensor defective Replace
Hesitationat high speeds Fueltank strainerclogged Clean or replace

(Fuel pressuretoo low)
Fuel pipe clogged Clean or replace
Fuel filter clogged Replace
Defectivefuel pump system Check and replace
Fuel PressureControl Valve Replace

leaking
Hesitationat high speeds Powersupplyor groundcircuitfor Check and corrector replace

(Fuel injectornot working MultiportFuelInjectionSystem
normally) shortedor open
Cableof MultiportFuel Injection Corrector replace

Systemdisconnectedor defective
Hesitationat high speeds EngineControl Moduledefective Replace
ThrottlePositionSensorcircuit Corrector replace

openor shorted
ThroülePositionSensordefective Replace
EngineCoolantTemperature Correct or replace

Sensorcircuitopenor shorted

Sensor defective
MAP Sensorcable open or shorted Corrector replace
MAP Sensor defective Replace
IATSensorcircuitopenor shorted Corrector replace

IAT Sensor defective Replace
KS Circuitopenor shorted Corrector replace

KS Modulecircuitopenor shorted Corrector replace

Throttlevalve not wide opened Check and corrector replace

Air CleanerFilterclogged Replacefilterelement
Powersupplyvoltagetoo low Check and corrector replace
Enqine LacksPower
nqrne LacKs P
Trouble in fuel system Fuel PressureControl Valve Replace
not workingnormally
Fuel injectorclogged Clean or replace

Fuel pipe clogged Clean
Fuel filtercloggedor fouled Replace
Fuelpumpdrivecircuitnot Correct or replace

workingnormally
Fuel tank not sufficientlybreathing Clean or replace
due to clogged Evaporative
EmissionControlSystemcircuit
Water in fuel system Clean

Inferiorqualityfuel in fuel system Use fuel of specifiedoctane rating
EngineControlModulesupplied Correctcircuit
poor voltage
ThrottlePositionSensorcable Corrector replace

disconnectedor broken
ThrottlePositionSensordefective Replace
Sensornotworkingnormally
6A

Sensor Replace
notworkingnormally
EngineCoolantTemperature Correct or replace
Sensorcircuitopenor shorted
Sensordefective
EngineControlModuledefective Replace
Troublein intakeor exhaust Air CleanerFilterclogged Replacefilterelement
system
Air duct kinked or flattened Correct or replace

lgnitionfailure Refer to Hard Start
Heat range of spark plug Installspark plugs of adequate
inadequate heat range
ElectroniclgnitionSystem Replace
with module
Engineoverheating Levelof EngineCoolanttoo low Replenish
Thermo switch or fan motor Replace
defective
Thermostatdefective Replace
EngineCoolantpump defective Corrector replace
Radiatorclogged Clean or replace
Radiatorfiller cap defective Replace
Levelof oil in enginecrankcase Changeor replenish
too low or wrong oil in engine
Resistancein exhaustsystem Clean exhaustsystem or replace

increased defective parts
ThrottlePositionSensor AdjustWideOpenThrottte
adjustmentincorrect switchsetting
ThrottlePositionSensor circuit Correct or replace
open or shorted
Cylinderhead gasketdamaged Replace

Engineovercooling Thermostatdefective Replace(Use a thermostatset to
open at 92"C (197.0"F))
Enginelackscompression Refer to Hard Start
Others Tire inflationpressureabnormal Adjustto recommend
pressures
Brake drag Adjust
6A-10 MY99RodeoServiceManual

Clutch slipping Adjust or replace
Levelof oil in enginecrankcase Correctlevel of engineoil

too high

Valvedefective
EngineNoisy
Abnormalenginenoiseoftenconsistsof variousnoisesoriginatingin rotatingparts,slidingparlsand othermoving
partsof the engine.ll is, therefore,advisableto locatethe sourceof noisesystemat¡cally.

Noisefrom crankjournalsor Oil clearanceincreaseddue Replace crank bearingsand
from crank bearings to worncrankjournalsor crankshaftor regrindcrankshaft
(Faultycrank journalsand crankbearings and installthe over size bearing
crankbearingsusuallymake
dull noisethat becomesmore
evidentwhen accelerating)
Crankshaft
out of round Replacecrank bearingsand
crankshaftor regrindcrankshaft
and installthe over size bearing
Crank bearingseized Crank bearingseized Replace

crank bearingsand crankshaft
or regrindcrankshaftand install
the over size bearing
TroubleshootingProcedure
Shortout eachsparkplug in sequenceus¡nginsulatedsparkplugwire removers.Locatecylinderwithdefective
bearingby listeningfor abnormalnoisethat stopswhensparkplugis shortedout.

Noisefrom connectingrods or Bearingor crankshaftpin worn Replaceconnectingrod bearings
from connectingrod bearings and crankshaftor regrind
(Faultyconnectingrods or crankshaft and install the
connectingrod bearings under size bearing
usuallymake an abnormal
noiseslightlyhigherthan the
crankbearingnoise,which
becomesmore evidentwhen
engineis accelerated)
Crankpinout of round Replaceconnectingrod bearings

and crankshaftor regrind
crankshaft and install the
under size bearing

Connectingrod bent Corrector replace
Connectingrod bearingseized Replaceconnectingrod bearings
and crankshaftor regrind
crankshaftand install the
under size bearing
Abnormalnoise stops when the spark plug on the cylinderwith defectivepart is shortedout.

Pistonand cylinder Pistonclearanceincreaseddue Replacepistonand cylinderbody
(Faultypistonor cylinder to cylinderwear
usuallymakesa combined
mechanicalthumpingnoise
which increaseswhen engine
is suddenlyacceleratedbut
diminishesgraduallyas the
enginewarms up)
Pistonseized Replacepistonand cylinderbody

Piston ring broken Replacepistonand cylinderbody
Piston defective Replacepistonsand others
short out each spark plug and listenfor change in enginenoise.
Condition Possible Cause Correction

Pistonpin noise Pistonpin or pistonpin holeworn Replacepiston,pistonpin and
(Piston makes noise each connectingrod assy
time it goes up and down)
The slappingsound stopswhen sparkplug on bad cylinderis shortedout.

Tlmingbelt noise Timingbelt tensionis incorrect Replacepusher or adjust the
tensionpulleyor replacetimingbelt
Tensionerbearing defective Replace
Timing belt defective Replace

Timing wheels defective Replace
Timingbelt comes in contact Replacetiming belt and

with timing cover timing cover
Valve noise Valve and valve guide seized Replacevalve and valve guide

Valve spring broken Replace
Valve seat off-positioned Correct
Crankshaftnoise Crankshaftend play excessive Replacethrustbearing
(noise occurs when clutch
is engaged)
Engineknocking Pre-ignition
dueto useof spark InstallSparkPlugsof adequate
plugsof inadequateheatrange heat range
Fuel too low in octane rating Replacefuel
Wide Open Throttleenrichment Referto Section6E. Click
system failure heretor 2.2L.
Clickherefor 3.2L.
Selectionof transmission Cautionoperatorof incorrect
gear incorrect gearselection
Engine overheating Refer to Engine Lacks Power
Others Water pump defective Replace
Drive belt slipping Adjust tension of drive belt or
replace drive belt
AbnqrmalGombustion
Troublein fuel injectionsystem Fuel pressurecontrolvalve Replace
defective
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injectorclogged Clean or replace
Fuel pump relay defective Replace
Power supplycablefor fuel pump Reconnect,corrector replace
loosely connectedor defective
ManifoldAbsolutePressure Corrector replace

Sensor defective
EngineCoolantTemperature 'Corrector replace

(ECT)Sensorcircuitopen
or shorted
ECT Sensor defective Replace
ThrottlePositionSensor Reconnect
adjustmentincorrect
ThrottlePositionSensordefective Replace
ThroülePositionSensorconnector Reconnect
looselyconnected
VehicleSpeed Sensorcable Correct or replace

looselyconnectedor defective
VehicleSpeedSensorlooselyfixed Fix tightly
VehicleSpeed Sensorin wrong Replace

contact or defective
EngineControlModulecable Correct or replace

looselyconnectedor defective
Troublein emissioncontrol Heated Oxygen Sensor Correct or replace

system circuitopen
HeatedOxygen Sensordefective Replace
Signalvacuum hose looselY Correct or replace

fitted or defective

Valve defective
ECT Sensorcircuitopenor shorted Correct or replace
ECT Sensordefective Replace
system
Evaporator Refer to Section6E. Click
here tor 2.2L.
Clickhere for 3.2L.
Troublein ignitionsystem Referto EngineLacks Power
Troublein cylinderheadParts Carbondepositsin combustion Removecarbon

chamber
Carbondepositon valve,valve Removecarbon

seat and valve guide
Enoine Oil
not ne u ll u onsum Excessive
Consumption
Oil leaking Oil pan drain plug loose Retightenor replacegasket
Oil pan settingbolts loosened Retighten
Oil pan gasket broken Replacegasket
Frontcover retainingbolts loose Retightenor replacegasket

or gasket broken

Head cover retainingbolts loose Retightenor replace gasket
or gasket broken
Oil filter adapter cracked Replace
Oil filterattachingsbolt looseor Retightenor replaceoil filter

rubber gasket broken
Crankshaftfrontor rearoil Replace oil seal

seal defective
Oil pressure
unitlooseor broken Retightenor replace
Blow-bygas hose broken Replace hose
Engine/Transmission
coupling Replaceoil seal
area
Oil leakinginto combustion Valve stem oil seal defective Replace
chambersdue to poor seal
in valve system
Valve stem or valve guide worn Replacevalve and valveguide

Oil leakinginto combustion Cylindersand pistonsworn Reborecylinderand replace
chambersdue to poor seal excessively pistons and others
in cylinderparts
Pistonringgapsincorrectly Correct
positioned
Pistonringssetwithwrongsideup Correct
Pistonring sticking Reborecylinderand replace
pistons and others
Pistonring and ring grooveworn Replacepistons and others

Returnportsin oil ringsclogged Clean piston and replacerings
Crank case ventilation, PositiveCrankcaseVentilation Clean
PositiveCrankcaseVentilation Hose clogged
Systemmalfunctioning
Others lmproperoil viscosity Use oil of recommended

S.A.E. viscosity
Continuoushigh speed driving Continuoushigh speed operation

and/or severe usage such and/orsevereusage will normally
as trailertowing cause increasedoil consumption
6A-1
ue Consumot¡
Fuel nsum on Excessive
- Condition PossibleCause Correction
Troublein fuel system Mixturetoo richor too leandueto Referto AbnormalCombustion
troublein fuelinjectionsystem
Fuelcutfunctiondoesnotact Referto AbnormalCombustion
Troublein ignitionsystem Misfiringor abnormalcombustion Referto HardStartor Abnormal
due to troublein ignitionsystem CombustionTroubleshooting
Guide
Others Engineidle speed too high Reset ldle Air ControlValve
Returningof accelerator Correct
controlsluggish
Fuel system leakage Corrector replace

Clutchslipping Correct
Brake drag Correct
Selectionof transmission Cautionoperatorof incorrect
gear incorrect gear selection
Excessive Exhaust Gas Referto AbnormalCombustion
Recirculationflow due to trouble in
ExhaustGas Recirculation system
Oil Problems
Oil pressuretoo low Wrong oil in use Replacewith correctengine oil
Relief valve sticking Replace
Oilpumpnotoperating
properly Correct or replace
Oil pumpstrainerclogged Cleanor replacestrainer
Oil pumpworn Replace
Oil pressuregauge defective Corrector replace
Crankshaftbearingor connecting Replace
rod bearing worn
Oil contamination Wrongoil in use Replacewith new engineoil
Oil filter clogged Replaceoil filter
Cylinderhead gasketdamage Replace gasket
Burnedgases leaking Replacepiston and piston rings
or reborecylinders
Oil not reachingvalve system Oil passage in cylinderhead or Clean or correct
cylinderbody clogged
6A-f 6 MY99RodeoServiceManual
EngineOil PressureCheck
1. Checkfor dirt,gasolineor waterin the engineoil.
a. Checkthe viscosityof the oit.
b. Changethe oil if the viscosityis outsidethe specifiedstandard.
c. Referto the Maintenance and Lubricationsect¡onof this manual.
2. Checkthe engineoil level.
The levelshouldfall somewherebetweenthe ADDand the FULLmarkson the oit leveldipstick.
lf the oil leveldoesnot reachthe ADD markon the oil leveldipstick,eng¡neoil mustbe added.
3. Removethe oil pressureunit.
4. Installan oil pressuregauge.
5. start the engineand allowthe engineto reachnormaloperat¡ngtemperature (Aboutgo"c).
6. Measurethe oil pressure.
Oil pressuréshould bé: 150 kPa (21.8ps¡) at ¡dle speed.
7. Stopthe engine.
8. Removethe oil pressuregauge.
9. Installthe oil oressureuntt.
10. Startthe engineand checkfor leaks.
Malfunction
IndicatorLamp
The instrumentpanelCHECKENGINEMaffunct¡on IndicatorLamp(MlL)illuminates
by selfdiagnosticsystem
whenthe systemchecksthe startingof engine,or sensesmalfunctions.

CHECKENGINEMILdoes Bulb defective Replace
not illuminate
at the starting
of engine
MIL circuitopen Corrector replace
Commandsignalcircuitto operate Corrector replace
self diagnost¡csystem shorted
EngineControlModule (ECM) Correct or replace

cable looselyconnected,
disconnectedor defective
ECM defective Replace

C H ECKENG INEMIL Deteriorationheated oxygen Replace
illuminates,
and stayson sensorof internalelement
Heated oxygen sensor connector properly

Reconnect
terminalimpropercontact
Heated oxygen sensor lead Correct

wire shorted
Heatedoxygensensorcircuitopen Corrector replace
Deterioration
enginecoolant Replace
temperaturesensorof internal
element

Enginecoolanttemperature Reconnectproperly
sensorconnectorterminal
impropercontact
Enginecoolanttemperature Correct
sensorlead wire shorted
Enginecoolanttemperature Correct or replace

sensorcircuitopen
Throttlepositionsensoropen Corrector replace

or shortedcircuits
Deteriorationof crankshaft Replace

positionsensor
Crankshaftpositionsensorcircuit Correct or replace

open or shorted
Vehiclespeed sensorcircuitopen Correct or replace

Manifoldabsolutepressuresensor Corrector replace
circuitopen or shorted
Intakeair temperaturesensor Corrector replace

circuitopen or shorted
Fuelinjectorcircuitopenor shorted Corrector replace
ECM drivertransistordefective ReplaceECM

Malfunctioning
of ECM RAM ReplaceECM
(RandomAccess Memory)or
ROM (ReadOnly Memory)
CylinderHeadCover
Removal
1. Disconnectbatterygroundcable.
2. DisconnectPCV hosefromcylinderheadcover.
3. Removeintakeduct.
4. Removeleftsidegroundcablefromcylinderheadcoverand disconnectgroundcableconnectoron the
lefts¡dewheelarch. Removerights¡degroundcablefromgeneratorstay anddisconnectgroundcable
connector on the rightsidewheelarch.
5. Disconnect three(black,greenand bluecolors)enginewire harnessconnectors from chassisharnesso{
left rearside of comoartment.
6. Disconnectcoolingfan wireharnessconnectorfromcoolingfan on left sidetop of fan shrouo.
7. Movedrive belt tensionerto looseside usinqwrenchthen removedrive belt.
8. RemovePCV hosefromcylinderblock.
9. Removeintakeduct stayfrom cylinderhead.
10. Removetwo bollsfor removeignit¡oncablecoverfromcylinderheadcover.
11. Disconnect
ignitioncablefromignitionplug.
l2' Disconnect
camshaftpositionsensorharnessandcrankshaftanglesensorharnessfrombehindgenerator.
13. Removefour boltsand removelhe crankshaftoullév
020RW014
14. Removetiming belt front cover.
15. Loosefixingbolt of timingbelt rear coverthen removethe camshaftanglesensor.
1j
16. Removeten cylinderhead coverfixing bolts and removethe cylinderhead cover.
020Rw012
6A-19
lnstallation
1. Installthe camshaftpositionsensorand tightentimingrearcoverbolt.
Torque: 8 N-m (S.9 tb ft)
020RWo12
2. Installthe cylinderhead cover and tightenboltsto the specifiedtorque.
Torque: 8 N-m (S.9 tb ft)
3. Installthe timingbelt frontcoverthen tightenfixingboltsto the specifiedtorque.
Torque: 6 N-m (4.4 tb ft)
4. Installthe crankshaftpulley,tightenfixingboltsto the specifiedtorque.
Torque: 20 N-m (14 lb f0
5' Movedrivebelttensionerto looseside usingwrenchtheninstallthe drivebeltto normal

Dosition.
6. Connectignitioncableto ignitionplug.
7. Installignitioncable coverto cylinderhead cover and tightentwo bolt to the specifiedtorque.
Torque: 3 N-m (2 lb ft)
8. Installintakeduct bracketto cylinderblock.
9. InstallPcv hose flangeto cylinderblockto the specifiedtorque.
S::l:/
10. Connectcoolingfan wire harnessconnectorto coolingfan on left s¡detop of fan shroud.

11. Connectleft side groundcableto cylinderheadcoverand connectotherside connectorto lett side
wheelarchterminal.
Connectrightside groundcableto generatorstayand connectotherside connectorto rightside wheel
archterminal-
12. Connectthree(black,greenand bluecolors)enginewire harnessconnectorto chassisharnessof left rear
side of enginecompartment.
13. Installintakeduct.
14. ConnectPCV hoseto cylinderheadcover.
15. Connectbatterygroundcable.
ExhaustManifold
Removal
2. DisconnectPCV hosefromair intakeduct.
3. Removea nut from air intakeductbracketand loosenhoseclampon throttlebody.Removeair intake
duct assemblywith air cleanercover.
4: Removeair intakeductbracketwithgroundcable.
5. Removefourfixingboltson exhaustmanifoldheatprotector.
MY99RodeoServiceManual 6A-21
6. Removefixingfour nutsfromflangeof frontexhaustpipeand removefixingboltsfromsilencerside.
7. Removeten exhaustmanifoldfixingnuts then removeexhaustmanifold.
Installation
1. Installexhaustmanifoldand tightenfixingnuts to be tightenedin three steps.
. Tightening sequence:
Stepl: JGHBDCJGBD
Step 2: A B C D E F G H J K
Step3: ABCDEFGHJK
Tightening torque:
Step 1z 14 N-m (10 lb ft)
Step 2: 20 N-m (14 lb ft)
Step 3: 20 N-m (14 lb ft)
2. lnstallfront exhaustpipe to exhaustmanifoldand tightenfixingnut to the specifiedtorque.

Torque: 25 N-m (18 lb
3. T¡ghtensilencersidebolt to the specifiedtorque.

4. lnstallexhaustman¡foldheatprotectorand tightenbolt.
Torque: I N-m (5.9 lb ft)
5. Install¡ntakeduct bracketw¡thgroundcable.
6. Installintakeductassemblyto throttlebodyand air cleanerthentightennul to the intakeductbracket
and clampon the throttlebodyside,also clampair cleanercover.
7. ConnectPCV hoseto air intakeduct.
GrankshaftPulley
Removal
batterygroundcable.
1. Disconnect
2. Movedrivebelttens¡onerto looseside by usingwrenchthen removedrivebelt.
3. Removefour crankshaftpulleyfixingbolts,removecrankshaftpulley.
# -_vr'
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020RW014
lnstallation
1. Installthe crankshaftpulleyto crankshaftflange.
2. Tightenfour bolt to the specifiedtorque.
3. Movedrivebelttensionerto looseside by usingwrench,then installdrivebeltto normalposition.
033RW001
lntake Manifold
Removal
2. Remove PCV hosefrom air intakeduct.
3. Removea nut from air intakeduct bracketand loosenhose clamp on throülebody. Remove air intake
duct assemblywith air cleanercover.
4. Drain enginecoolant.
5. Remove water hoses from throttlebody.
6. Disconnectthe connectorfor throttlepositionsensor,idle air controlvalvesensorfrom throttlebody.
7. Removefuel pipejoint eye boltsfrom fuel rail and disconnectwire harnessfrom fuel injector.
ew
8. Disconnecthosefrom fuel pressureregulatorthen removefuel rail assembly.
9. Remove throülevalve controlcable from throttlebody.
10. Removefixingboltsfor generatorbracket.
\-
11. Removewater pipe fixingbolt then removewaterpipe.

12. Removefixingboltfrom bracket(Betweencylinderblock and intakemanifold)of intakemanifoldside.
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13. Removeignitioncoil bracketfixingbolt.

14. Removebolt and seven nuts,and removeintakemanifold.
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lnstallation
1. Installintakemanifoldwith gasketto cylinderhead,tightenbolt and nuts to the specifiedtorque.
Torque:22 N-m (16 lb ft)
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2. Installignitioncoil bracketfixingbolt.
3. Installintakemanifoldbracket,tightenbolt.
Torque: 22 N-m (f O lb ft)
4. Installwater pipe to intakemanifold.

5. Installgeneratorbracketand tightengeneratorbracketbolts.
Torque:
Long bolts: 35 N-m (25 lb ft)
Short bolts: 20 N-m(14 lb ft)
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6. Installfuel railassemblyto intakemanifoldand connecthosebetweenfuel pressureregulatorand throttle

body.
7. Installfuel pipe and tightenjoint eye bolt and connectfuel injectorharness.
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8. Connectthe connectorfor throttlepositionsensorand idlea¡rcontrolvalvesensorto throttlebody.
9. Installwaterhosesto throttlebody.
10. Installintakeductassemblyto throttlebodyand air cleanerthentightennutto the intakeductbracketand
clampon the throttlebodyside and air cleanerside.
Torque: 7 N-m (5.1 lb ft)
11. InstallPCV hoseto air intakeduct.
12. Installthrottlevalvecontrolcableto throülebody.
13. Confkmthe free play of throttlevalvecontrolcable.
F¡ee play: 5.7 to 6.3 mm
14. Fill enginecoolantto full levelfrom radiatorfiller neck.
CylinderHeadAssembly
Removal
batterygroundcable.
1. Disconnect
2. Disconnect
connectorof intakeairtemperature
sensorfromintakeair duct.
6A-28 MY99RodeoServiceManua
3. Remove PCV hose from air intakeduct.

4. Removenut from air intakeduct bracketand loosenhose clamp on throttlebody. Removeair intake
duct assemblywith air cleaner cover.
5. Remove intake air duct bracketfrom cylinderhead.
6. Drain enginecoolant.
7. Move drive belt tensionerto looseside using
usino wrenchthen remove drive belt.
8. Removeradiatorupperhosefromengineside.
9. Removefournutsof exhaustfrontpipe.
10. Removethreeboltsfromgenerator
bracketthenremovethe generator
withbrackets.
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11. Disconnectcrankshaftangle sensorconnector.

12. Disconnectknock sensorconnector.
13. Remove heater hose from adapterside.
14. Removeheaterhose from water pipe side.
15. Removewater hose betweenwater pipe and throttlebody.
6A-2f
16' Removefuel pipe joint eye boltsfrom fuel rail assemblyand removefuel pipe bracketwith
electricground
cable.
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042RW00
17. Disconnectconnectorfor evaporationvalve.
18. Removecanisterhose.
19. Removefixing nut of intakemanifoldstay from cylinderblockside.
20. Removetwo boltsfrom intakemanifoldfor water pipe supportand removecylinderhead assembly

2 1 . Removeengineharnesscoverand disconnectthree connectorsfrom chassisharnesson left rear side
enginecompartment.
22. Disconnectconnectorfor powersteeringpump pressureswitch.
020Rw014
24. Removetwo bolts and nut then removetimingbelt front cover.

25. Removeventilationhosefrom cylinderblock side and from cylinderhead side.
26. Removetwo bolts,ignitioncable coverand removeignitioncablesfrom sparkplug.
27. Disconnectcamshaftangle sensorconnector.
28. Removeten bolts and removecylinderhead cover.
29. Removefixingbolt of timingbelt tensionerthen removetiming belt tensioner.
30. Removeümingbelt.
CAUTION!
. Do not bend or tw¡st belt, otherw¡seits core could be damaged.The belt should not be
bent at a radius less than 30 mm.
. Timing belt drive gear counterholdwith J-f2620.
. Do not allow oil or other chemical substancesto come in contact with the belt, They
will shorten the life.
. Do not attempt to pry or stretch the belt with a scréw dr¡ver or any other tool during
installat¡on.
. Store timing belt in cool and dark place. Neverexpose the belt direct sunl¡ght or heat.
1. Removetwo idle pulleys,the left s¡dewith idlepulleybracket.
2. Removetwo boltsand studboltand removetimingbeltrearcover.
3. Removecamshaftangle sensor
4. Disconnectengineoil pressureswitchconnector.
5- Removecamshaftassemblyexhaustside.
6. Use J-42623to removeten cylinderhead fixingbolts
2610
Installation
1. Put cylinderhead gasketon the cylinderblock.
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2. Installthe cylinderhead assembly,tightencylinderhead boltsby four stepstighteningmethodin the

followingsequenceto the specifiedtorque. (use J-42623)
Torque: 25 N-m (18 lb ft) + 90o + 90o + 90o
106237
95148
3. Installcamshaftassemblyexhaustside and tightencamshaftbracketboltsin the sequenceto the

specifiedtorque.
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015RW014
4. Connectengineoil pressureswitchconnector.
5. Installcamshaftangle sensor.
6. Installthe timingbelt rear cover and tightenthreeboltsto the specifiedtorque.
Torque:
M6 bolt: 6 N-m (4,4 lb ft)
M8 bolt: I N-m (5.8 lb ft)
020Rw012
7. Installleft side idle pulleywith idle pulleybracket,tightento the specifiedtorque and installright side idle
pulleyand tightento the specifiedtorque.
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8. Installtimingbelttensionerthentightenit temporarilyuntilmakealignmenttimingbelt.
9. lnstallthe cylinderheadcoverand t¡ghtenfixingbolttemporally.
10. lnstallthe timingbelt and performtimingbelt settingprocedureas follows:
. Bringthe eng¡netop deadcenterNo.1cylindercompression strokeby rotaüngthe eng¡nein
the directionof normalooeration.
The engineis ¡nthis positionwhenthe notcheson the camshaftpulleysalignwiththe markson
the cyl¡nderheadcove(1),Checkthe crankshaftpulleytimingmarkis aligned(2) alsocheckfor
waterpumppositioningensuretabs are aligned(3).
. Rotatethe enginetwo lull lurnsin the directionof normaloperationuntilthe eng¡neis againat top
dead center,No.1cylinderfiringbeingcarefulthatall movementis in a clockwisedirection.
lf the engineis turnedtoo far, do not turn backwards,but continueto turn in the same direction
untilthe marksare again in line.
1
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11. Place J-43037to betweenintakeand exhaust of camshaftdrive gear to preventcamshaftdrive gear

movementduringtimingbelt setting.
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'12.Setthetim¡ngbeltshownin the illustration,ensurethat tensions¡deof the timingbelt¡stautand movethe

limingbelttensionadjustmentleverclockwise,untilthepointerof the tensioneris flowing.
H
014RW070
For used timingbelt (over60 minutesfrom new): the pointerwill be approx.4 mm(0.16in) to the left of
the centerof the V notchwhen viewedfrom the front of the engine.
For new timing belt: The pointermust be at the centerof V notchwhen viewedfrom the front of the :;::
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0148W062
13. Tightenfixing bolt of timing belt tensionerto the specifiedtorque.

020RW)10
14. Tlghtencylinderhead coverto the specifiedtorque.

15. Connectcamshaftanglesensorconnector.
16. lnstallthe ignitioncableto sparkplug.
17. Installignitioncable coverand tightentwo bolts.
18. Installventilationhosesto cylinderblockside and cylinderhead side.
19. Installtimingbelt front coverand tightentwo boltsto the specifiedtorque.
20. Installcrankshaftpulleyand tightenfour bolts.
21. Connectconnectorfor powersteeringpumppressureswitch.

22. Connectengineharnessconnectorto chassisharnessof the left rearof enginecompartment
and install
engineharnesscover.
23. Installtwo boltsto intakemanifoldfor waterpipe support.
24. Installfixing nut of intakemanifoldstay to cylinderblock.
25. lnstallcanisterhose.
26. Connectconnectorfor evaporation valve.
27. Installfuelpipeio¡nteyeboltsto fuel railassemblyand installfuel pipebracketwithelectricgroundcable.
Torque:25 N-m (18lb ft)
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28. Installwater hose betweenwater pipe and throttlebody.
29. Installheater hose to water pipe side.
30. Installheater hose to adapter side.
3 1 . Connectknock sensorconnector.
32. Connectcrankshaftangle sensorconnector.
33. lnstallgeneratorwith bracketand tighten three bolts.
Torque:
35 N-m (25 lb ft) for Long bolt
20 N-m (14 lb ft) for Short bolt
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34. Installexhaustfront pipe to exhaust manifoldand tightenfour nuts to the specifiedtorque.

35. Installradiatorupper hoseto engine.

36. Move drivebelt tensionerto looseside usingwrenchthen installthe drivebeltto normalposition.
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37. Installintakeair duct bracketto cylinderhead.

38. Installair intakeduct assemblyw¡thair cleanercoverto throttlebodyand tightennutto the air intake
duct bracketthen tightenhoseclamp.
Torque:
7 N-m (5.1 lb ft) tor nut
3 N-m (2.2 lb ft) for hose ctamp bott
39. InstallPCV hoseto air intakeduct_
40. Connectconnectorof intakeair temperature sensoron intakeair duct.
., 42. Fil enginecoolantto full levelin the eng¡necoolantreservoirtank.
Timing Belt
Removal
2. Movedrivebelttensionerto loosesideusingwrenchthen removedrivebelt.
3. Removeeng¡neharnesscoveranddisconnect threeconnectorsfromleft rearsideof enginecompanment.

4. Removefour boltsand removecrankshaftpulley.
020RW014
5. Disconnectthree connectorsof eng¡neharnessfrom chassis harnessof left rear side of engine
compartment.
6. Removenut and removeeng¡neharnesscoverfrom front of engine.
MY99 Rodeo Service Manual 6¡
7. Removetwo bolts then removetiming belt front cover.

8. Removefixingbolt of timingbelt tensionerthen removetimingbelttensioner(1).
9. Removelimingbelt.
CAUTION!
. Do not bend or tw¡st belt, otherw¡seits core could be damaged.The belt should not be
bent at a radius less than 30 mm.
. Tim¡ng belt dr¡ve gear counterholdwith J-42620.
. Do not allow oil or other chem¡calsubstancesto come in contact with the belt. They
will shorten the l¡fe.
. Do not atlempt to pry or stretch the belt w¡th a screw driver or any other tool during
installation.
. Store t¡ming belt in cool and dark place. Neverexposethe belt direct sunlight or heat.
Installation
1. Installtim¡ngbelttensionerthentighten¡t temporarilyuntilmakealignmenttimingbelt.
2. Installthe timingbelt and performtimingbelt settingprocedureas follows:

1. Bringthe enginetop dead centerNo.1 cylindercompressionstrokeby rotatingthe enginein
the directionof normaloperation.
The engine is in this positionwhen the notcheson the camshaftpulleysalignwith the marks on
the cylinderhead cover(1),Checkthe crankshaftpulleytimingmark is aligned(2) also check for
water pump positioningensuretabs are aligned(3).
1
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MVgg Rodeo Service Manual 6A-43
2. Place J-43037 between intake and exhaust of camshaft drive gear for prevent to camshaft
drive gear movementduring timing belt setting.
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3. Set the timingbelt shownin the illustration,ensurethat tensionside of the timingbelt is taut and
movethe timingbelttensionadjustmentleverclockwise,untilthe pointerof the tensioneris flowing.
J-43037
For used timingbelt (over60 minutesfrom new):The pointerwill be approx.4 mm(0.16in) to the
left of the centerof the V notchwhen viewedfrom the frontof the engine.
For newtimingbelt:The pointermustbe at the centerof V notchwhenviewedfrom,n" rrJli"t"

of the engine.
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014RW062
3. Tightenfixingbolt (1) of timingbelt tensionerto the specifiedtorque.

020RW010
4. Installtimingbelt front coverand tightentwo boltsto the specifiedtorque.
Torgue: 6 N-m (4.4 lb ft)
5. Installengineharnesscoverto fronttop of engineand tightennut to the specifiedtorque.
6. Installcrankshaftpulleyand tightenfour bolts.
020Hw014
7. Movedrivebelt tensionerto looseside usingwrenchthen installdrive beltto normalposition.
8. Connectengineharnessthreeconnectorto chassisharnessof left rearsideof enginecompartment.

9- Connectbatterygroundcable.
Camshaft
Removal
2. Removecylinderheadcover.
Referto removalprocedurefor CylinderHeadCover¡nthis manual.
3. Removetimingbelttensionerand removeümingbelt.
020Rw01
4. Useadiustablewrenchto hexagonalportionof camshaft,and removefixingboltfromfrontend ol camshaft.
014RW074
5. Removecamshaftdrive gear from intake and exhaustcamshaft.
6. Removetwenty fixing bolts from intake and exhaustcamshaftbracketon the cylinderhead,then remove
camshafts.
01 1RW015
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into cylinder head.
1. Removeoil seal from camshaft.
Installation
1. Clean surfaceof camshaftbracketand HLA.
2- Apply engine oil to journal surfaceof camshaftbracketand HLA.
3. Installcamshaftto cylinderhead.
4- Installcamshaftbracketaccordingto numericalas shown in the illustration.
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rront
Intake:6 to 10 from front.
014Rw052
Camshaftoil seal installation

area on the cylinderbody of No.1, No.6and camshaftbracketrear
side plug portionmust be appliedHN1023or equivalent as in the illustration.
014RW073
5- Tightencamshaftbracketboltsto the specifiedtorqueby sequencein the illustration.

Torque: I N-m (5.9 ¡b ft)
6. Use J-42609for installationcamshaftoil seal.
7. Installthe camshaftdrive gear. Align the timingmark betweennotch on the camshaftdrive gear(1,o'o'*0"
and lug on the camshaftbracket(2).
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Alsoaligna guidehole on the camshaftdrivegear markedlN for intakeand EX for exhaustto guide pin on
the camshaftwhen installingthe camshaftdrive gear.
014RW07
8. Tightencamshaftbracketfixingbolt to the specifiedtorque.

Torque: 50 N-m (36rb fr)
9. Installtimingbelt.
procedurefor TimingBeltin this manual.
Referto installation
10. Installcylinderheadcover.
procedurelor CylinderHeadCoverin this manual.
Referto installation
11. Connect batterygroundcable.
EngineAssembly
Removal
1. Disconnect batterygroundand positivecable.
2. Removebattery.
3. Makealignmentmarkon the enginehoodand hingesbeforeremovalin orderto returnthe hoodto
originalpositionexactly.
4. Removeenginehood.
5. Drainenginecoolanlfrom radiator.
6. Disconnect throttlevalvecontrolcablefromthrottlevalveon intakemanifold.
7. Removeair ductwith air cleanercover.
8. Removeair cleanerassembly.
9. Disconnectthree engineharnessconnectorsfrom chassisharnessof left rear sideenginecompartment.
10. Disconnectvacuum hose on the brake booster.
11. Disconnectcoolingfan harnessconnectoron the left of fan shroud.
12. Disconnectgroundcable connectorfrom left and rightof frontwheel arch upperside.
13. Removeclutchpipingbracketfrom right side of clutch housing.
14. Removefuel pipingbracketfrom transmission.
15. Removefour nuts from exhaustfront pipe exhaustmanifoldside and removetwo boltsfrom rearside of
exhaustfront pipe. Removeexhaustfront pipe.
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16. Removetransmissionmountingfixingbolts and nut from cross member.
17. Removetransmissionfront undercover from front portionof clutchhousing.

18. Disconnecttwo fuel pipesat rightside of transmissionby quicktype fuel hose connector.
CAUTION!Plug fuel pipe on engine side and fuel hose from fuel tank.
19. Disconnectcanisterhose next to fuel pipingconnector.
20. Removepropellershaftfixingbolt from rear side transmission.
21. Removefixingboltsbetweenclutchhousingand transmission,
then move transmission.
22. Removepowersteeringpump assemblythen placethe powersteeringpump alongwith piping.
23. Disconnecttwo chassisharnessconnectorsfrom rightrear side enginecompartment(underfuse box)

and removetwo harnessclips.
24. Removeenginegroundcablefrom chassisframe.
25. Removeradiatorlower hose from engineside.
26. Removetwo heaterhosesfrom rightside panel.
27. Removeradiatorgrille.
28. Removeharnessclipfrom behindrighthorn.
29. Removeenginemountingboltfrom chassisframeside.
022RW005
30. Liftup the engineassembly.
Installat¡on
CAUTION!When assemblingthe engine and transmi$s¡on,conf¡rmthat dowels have been mounted in the
specifiedposit¡onsat the eng¡neside. lf assembledin the conditionthat dowels have not b€en mountedin
the specifiedposition, transm¡ssiondamagecan result.
1. Position
the engineassembly in the enginecompartmenl.
2. T¡ghteneng¡nemount¡ngboltto frames¡deto the specifiedtorque.
022RW005
3. Installharnessclipbeh¡ndrighthorn.
4. lnstallthe radiatorgrilleand installflasherlampassembly.
5. lnstalltwo heaterhosesto rightside panel.
6. Installradiatorlowerhoseto engine.
7. Installenginegroundcableto chassisframe.
8. Connecttwo chassisharnessconnectorsto rightrearsideengineroom(underfuse box) and install
two harnessclips.
9. Installpowersteeringpumpassemblyand tightenfixingbolts.
10. Installtransmission procedurefor Transm¡ss¡on
assembly,referto installation section¡nthis manual.
11. Installpropellershaft,referto ¡nstallation
procedurefor Propellersectionin this manual.
12. Connectcanisterhosenextto fuel pipingconnector.
13. Connecttwo fuel pipesal rightsidetransmission by qu¡cktype connector.
14. Installtransmission frontundercoverto fronl portionof clutchhousing.
15. lnstalltransmission mountingfixingboltsand nutsto crossmember.
Torque: 50 N-m (36 ¡b ft)
16. Installexhaustfront pipe to exhaustmanifoldand silencer,then tightenfixingnuts and boltsto the

specifiedtorque.
Torque:
25 N-m (18 lb ft) for nut
68 N-m (50 lb ft) for bolt
17. Installfuel pipingbracketlo transmission.

18. Installclutchpipingbracketto rightside of clüch housing.
19. Connectgroundcableconnectorto left and rightof frontwheelarch upperside.
20. Connectcoolingfan harnessconnectoron the left of fan shroud.
21. Connectvacuumhoseto the brakebooster.
22. Connectthreeengineharnessconnectors to chassisharnessof left rearsideof enginecompartment.
23. lnstallair cleanerassembly.
24. Installair ductwith air cleanercoverto specifiedtorque.
Torque:
7 N-m (5.1 lb ft) for air duct f¡xing
3 N-m (2.2 lb ft) for air duct clamp bolt
25. Connectthrottlevalve controlcable to throttlevalve on the intake manifold.

Confirmthe free play of throttlevalve controlcable.
Free play: 5.7 to 6.3 mm
26. Installenginehood to originalposition.
Referto installationprocedurefor Bodysectionin this manual,
27. Installbattery,connectpositivecable and groundcable.
28. F¡llenginecoolantto full level in the coolantreservoirtank.
CylinderHead
CylinderHeadand AssociatedParts
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Legend
(1) CylinderHead Bolt
(2) CamshaftPulley Fixing Bolt
(3) CamshaftPulley
(4) CamshaftOil Seal
(5) CamshaftBracket Bolt
(6) CamshaftExhaust
(7) Camshaft lntake
(8) Tappet(HLA)
(s) Split Collar
( 10 ) ValveSpringand Spring Upper Seat
(11) Valve
Disassembly
Notice:
. Duringdisassembly,be sure that the valve train componentsare kept togetherand identifiedso that
they can be rcinstalledin theh or¡ginallocations.
. Beforc removingthe cylinderhead frcm the engine and before disassemblingthe valvemechanism,
performa comprcss¡ontest and note the results.
1. Removecamshaft pulleyfixingbolt(2),thenpulley(3).
2. Removecamshaftbracketfixingbolt(5),camshaftbracket,thencamshaftexhaust(6),and intakeside (7).
3. Removecylinderhead.
UseJ-42623.
4. Valvespring,valvespringcaps,compressvalvespring- useJ-8062(1)and AdapterJ-42619(2).
Valvekeeoers.
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0 11 R W 0 1
availableremoverpliers.ValvespringseatsfromcYlinder
b. Vatves,valve stem seals - use commercially
head.
Inspectionand Repair
1. Checklengthand width of cylinderhead sealingsurfacesfor deformationand diagonalsfor warpage -
use straightedge and feelergauge.
011RW011
2 . Heightof cylinderhead (sealingsurfaceto sealingsurface).

Dimension(l) - 134 mm
Reassembly
Valve,ValveGuidein this section.
1. Valves,valvestemseals.Referto ValveSpring,Oil Controller,
Valve,ValveGuidein this section.
2. Valvespring,valvespringcaps. Referto ValveSpring,Oil Controller,
MY99 Rodeo $ervice Manual 6A-59
3: Installtappet(HLA).
4. cylinder headwith new cylinderhead bortsto cylinderbtock.
Tightenthe bolts in 4 steps.
1st step: 25 N-m (18 lb ft)
2nd step: 900
3rd step: 90"
4th step: 90'
0 11 R W 0 1 4
5. camshaft in cylinderhead. Referto camshaft in this section.
6. Camshaftpulley. Refer to Camshaftin this section.
6A-60 My99 RodeoService Manual
ValveSpring,Valve,ValveGuide
ValveSpring,Valve,ValveGuide and Associated Parts
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Legend
(1) CamshaftPulley FixingBolts
(2) CamshaftPulley
(3) CamshaftBracketFixingBolt
(4) CamshaftAssemblylntake
(5) CamshaftAssemblyExhaust
(6) CylinderHead Bolt
(7) CylinderHead
(8) Tappet
(e) Split Collar
(10) SpringUpper Seat
(11) Valve Spring
(12) Oil Seal
(13) Spring Lower Seat
(14) Valve Guide
(15) Valve
Disassembly
1. Removecamshaftpulley(1), (2).
2. Removecamshaftassembly(lntake)(3), (4).
3. Removecamshaftassembly(Exhaustside) (5).
4- Removecylinderhead (6), (7).
5. Removetappet(8).
6. Use J-8062valve springcompressorand J-42619adapterto removesplitcollar(9).
0 11 R W 0 1
7. Removespringupperseat and valvespring(10),(11).

8. Valve,valveguide - use commerciallyavailableremoverpliers.
Valvespringlowerseat from cylinderhead.
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011RWq13
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ValveGuide
CAUTION!Takingcare not to damagethe valve seat contact surface,when remov¡ngcarbon adhering
to the valve head. Carefully inspect the valve stem tor scratchingor abnormalwear. lf these cond¡tions
are present,the valve and the valve guide must be replacedas a set.
Valve Seat
Valveseat w¡dth in cylinder head
Intake: f .0 to 1.5 mm (0.039to 0.0585in)
Exhaust: 1.7 lo 2.2 mm (0.0663to 0.0858in)
ValveSeat Insert Correction
Removethe carbonfrom the valveseat insertsurface.
Valve Seat Insert Replacement

1. Arc weld the rod at severalpoints.Be carefulnot to damagethe aluminumsection.
2. Allowthe rod to coolfor a few minutes.This will causethe valve seat to shrink.
3. Strikethe rod and pull it out.
4. Carefullycleanlhe valveseatpress-fitsectionon the cylinderheadside.

5. Heatthe press-f¡lsectionwithsteamor someothermeanslo causeexoans¡on.Coolthe valveseatwith
dry ice or someothermeans.
6. Insertthe press-fitsectionintothe valveseat hor¡zontally
7. LaDthe valveand the seat.
Reassembly
1. fnstafloil controller(3)andspringlowerseat (2). Usingo¡l controllerrcplact-tJ-42622,drivein a newoil
controller.
2. Installvalveto valveguide.Beforeinstallvalveguideapplyengineoil to the outsideof the valvestem.

3. lnstallvalve springto cylinderhead. Attachthe valvespringto the lowerspringseat.
6A-64 MY99Rod€o S€rvice l¡lanual
4. Installlowervafuespringseat,valvespringand uppervalvespringseatthenput splitcollarson the upper

springseat,us¡ngJ-8062valvespringcompressor for installthe splitcollars.
5. Installtappet.
6. Installcamshaftassembly.
. Referto installation
procedure
for Camshaftin this manual.
Camshaft
Camshaftand AssociatedParts
"-4
_@ a
g
e
B
-ñffiffi I
@
f,
$o
Legend
(1) CamshaftPulley FixingBolt
(2) CamshaftPulley
(3) Oil Seal
(4) CamshaftBracket
(5) CamshaftBracket Fixing Bolt
(6) CamshaftAssemblyExhaust
(7) CamshaftAssembly Intake
Disassembly
1. Removefixingbolt (1) for camshaftpulley(2).
2. Removeoil seal (3).
014RW035
3. Removeoil seal (3).

4. Removetwentyfixingbolts(5) from inlet and exhaustcamshaftbracket,then camshaftbrackets(4).
5. Removecamshaftassembly(6), (7).
Reassembly
1. Installcamshaftdrivegearassemblyand tightenthreeboltsto specif¡edtorque.
Torque: 50 N-m (37 lb ft) + 50" + 15"
2. Installcamshaftassemblyand camshaftbrackets,tightentwentyboltson one sidebankto the specified
rorque.
. Applyengineoil to camshafliournaland bearingsurfaceof camshattbracket.
. Aligntimingmarkon intakecamshaftand exhaustcamshaftto timingmarkon camshaftdrive
gear(onedot).
. Tightentwentyboltson numericalorderone sidebankshownin the illustration.
Torque: I N-m (6 lb ft)
. lf it requiredto replaceoil sealof camshaftdrivegear,useJ-42609for installthe oil seal.
. T¡ghtenboltfor camshaftdrivegearassemblypulleyto the specifiedtorque.
Torque: 50 N-m (37 lb tt) + 60o + 15o
Crankshaft
Crankshaftand AssociatedParts
Legend
(1) CylinderHead Assembly

(2) Oil Pump Assembly
(3) Pan
(4) Pan Support

(5) Oil Strainer
(6) BalanceUnit Assembly
(7) Pistonand ConnectingRod Assembly
(8) Main BearingCap
(e) Crankshaft
(10 ) CylinderBlock Assembly
Disassembly
1. Removecylinderheadassembly(1). Referto Cylinderheadin this manual.
2. Removeoil pan (3).
CAUTION!Takecare not to damageor deform the sealing flange surtace of crankcase,
3. Removeoil pan support(4).
4. Removeoil strainer(5).
5. Removeoil pumpassembly(5).
6. Balanceunitassembly.
7. Removepistonand connectingrod assembly(7). Referto Piston,PistonRingand ConnectingRod
in thismanual.
8. Removeflywheel.
9. Removerearoil seal and oil bafileplate.
10. Removemainbearingcap (8).
11. Removecrankshaft(9).
12. Removecrankshaftpulsepickupsensordisc.
Inspect¡on
and Repair
1. Crankshaft
Set the dial¡ndicatoras shownin the illustration
and measurethe crankshaftthrustclearance.lf the thrust
clearanceexceedsthe specifiedlimit,replacethe thrustbearingsas a sel.
Thrust Glearance
Standard: 0.01mm-0.02mm (0.0004in-0.0008¡n)
MY99 Rodeo Service Manual 6A-6S
Limit : 0.21 mm (0.0118in)
r.)
-.-i
--!r--
Ma¡nBear¡ngClearance
1. Removethe bearingcapsand measurethe oil clearance.
2. Removethe mainbearingcap fixingbolts.
Arrangethe removedmainbearingcaps in the cylindernumberorder.
Removethe ma¡nbearings.
3. Removethe crankshaft.
Removethe mainbearings.
4. Cleanthe upperand lowerbearingsas well as the crankshaftmainiournal.
5. Checkthe bearingsfor damageor excessivewear.
The bearingsmustbe replacedas a set if damageor excessivewear¡sdiscovered
duringinspection.
6. Setthe upperbearingsandthe thrustwashersto theiroriginalpositions.
Carefullyinstallthe crankshaft.
7. Set the lowerbearingsto the bearingcap originalposition.
8. Applyplastigageto the crankshaft journalunitas shownin the illustration.
s,l\í
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\ \\l.-.
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014RW055
9. Installma¡nbearingcaps,and tighteneach bolt to the specifiedtorque.
Main bearingcaps bolts
Torque:
lst step: 50 N-m (37 lb ft)

2nd step: 45o
3rd step: 15o
Torque : 39 N-m (291bft)
10.Measurethe plastigagewidth and determinethe oil clearance.lf the oil clearanceexceedsthe specified
limit, replacethe main bearingsas a set and/orreplacethe crankshaft.
Standard : 0.015 mm-0.04 mm (0.0007in-0.0016in)
Limit : 0.12 mm (0.00a7in)
014RWO77
11. Cleanthe plastigageÍromthe bearingsand the crankshaft.

Removethe crankshaftand the bear¡ngs.
Crankshaft(12) Inspect¡on
Inspectthe surfaceof the crankshaftiournaland crankpinsfor ex@ssivewearand damage.lnspectthe o¡lseal
fittingsurfacesfor excessivewearand damage.Inspectthe oil portsfor obstructions.
Inspect¡onand Repair
1. Carefullyset the crankshaft.Slowlyrotatethe crankshaftand measurethe runout.lf the crankshaftrunout
exceedsthe specif¡edlimit,the crankshattmustbe replaced.
Runout: 0.03mm (0.0012

in)
:i¡*ll
i\
2. Measurethe diameterandthe unevenwearof mainjournaland crankpin. lf the crankshaftwearexceeds
the spec¡f¡edlimit,crankshaftmustbe replaced.
Ma¡n¡ournal diameter: 57.934mm-57.980mm (2.259in-2.261in)
Crankp¡n d¡ameter:48.939mm-48.982 mm (1.909in.-1.91in.)
CrankshaftBearing Selection
Wheninstallingnew crankshaftbearingsor replacingbearings,referto the selectiontablebelow.Selectand
installthe new crankshaflbearinos.
CrankshaftGrindingDimensions mm (in)
Productionand Service
Crankshaftbearingjournaldia.
Standard size
white 57.974to 57.981 (2.260-2.261)

green 57.981to 57.988(2.261-2.2615)
brown 57.988to 57.995(2.2615-2.2618)
0.25(0.0097)
Undersize
green/blue 57,732to 57.738 (2-2515-2.2517)
brown/blue 57.738 to 57.745 (2.2517-2.252),

CrankshaftGrindingDimensions mm (in)
Undersize0.5 (0.0195)
green/white 57.482 to 57.488 (2.2418-2.242\
brown/white 57.488 to 57.495 (2.242-2.2423)
Guide bearingwidth
Standard size 25.950to 26.002(1.012-1.014)
Undersize0.25 (0.0097) 26.150to 26.202(1.019-1.021)
Undersize0.5 (0.0195) 26.350 to 26.402(1.027-1.029)
Notice: Take care to ensure the bearings are positioned correctly.

Crankshaftpulsepickupsensordisc inspect¡onand repair.
Inspectthe crankshaftpulsepickupsensordisc for excessivewear and damage.
Replacethe crankshaftpulsepickupsensordisc if the inspectionexceedswear and damage.
Reassembly
(12).
1. Crankshaft
. Installthe crankshaftpulsepickupsensordisc.
Torque:13 N-m(10lb ft)
. Installlhe mainbearingsto the cylinderblockand the mainbearingcaps.
. Be surethat they are positionedcorrectly.
. Applynew eng¡neoil to the upperand lowermainbear¡ngfaces.
Notice: Do not apply engine oil to the main bearingback faces.
.Carefullymountthe crankshaft.
.Applyengineoil to the thrustwasher.
.Assemblethe thrustwasherto the No.3bearingjournal.The oil groovesmustfacethe crankshaft.
.Tightenthe crankshaftbaringcap boltsin 3 steps:
2nd steo: 45"
3rd steo:15"
2. Rearoil seal(10).
. Coat lip of seal rings thinly with protectivegrease.

. fnstallseal ring into cylinderblock,use J-42616(1) and J-42613(2).
015RW009
3. Flywheel(9).
. Thoroughlycleanand removethe oil from the threadsof crankshaft.
. Removethe oil from the crankshaftand flywheelmountingfaces.
. Mountthe flywheelon the crankshaftand then installthe washer.
. Use stopper(J-42618)to hold the crankshaft.
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. Preventfrom rotating.
Tightenthe flywheelbolts in 3 steps:
2nd step: 30"
3rd step: 15"
Notice: Do not reuse the bolt.
4. Pistonand connectingrod assembly(8)
. Applyengineoil to the cylinderbores,the connectingrod bearingsand the crankshaftpins. Check
to see that the piston ring end gaps are correctlypositioned.
. Pistonringsposition(A) every 180".
Oil scraperrings(B) - offset25 to 50 mm/1 to 2 in. to left and rightfrom gap of intermediate
ring.
A
<-=A-
' Insertthe piston/connectingrod assembliesinto each cylinderwith the pistonring comp,""!,í.*o'u

The front marks must be facingthe front of the engine.
' Matchthe numberedcaps with the numberson the connectingrods. Alignthe punchedmarks
on the connectingrods and caps.
' Arrow (1) on pistonheadpointsto enginetimingside, bead on connectingrod pointsto flywheel
side.
. Tightenthe bolts in 3 steps:

2nd step: 45"
3rd step: 15'
5. Installthe balanceunit assemblyand tightenthe bolts in 2 steps:
2nd step: 45o
Referto the BalanceUnit Assemblysectionof this manual.
6. lnstalloil pump assembly(5), referto oil Pump in this manual.
7. Installoil strainer.
Torque: I N-m (5.8 lb tt)
8. Installoil pan supportand tightenthe bolts to the specifiedtorque.
Torque:20 N-m(14 lbft)

9. lnstalloil oan.
. Completelyremoveall residualsealant,lubricantand moisturefromthe sealingsurfaces.The
surfacesmustbe perfectlydry.
. Applya correctwidthbeadof sealant(TB-l207C or its equivalen0to the contactsurfacesof the
oil pan. Theremustbe no gapsin the bead.
. The oil pan supportmustbe installedwithin5 minutesatlersealantapplicaüon.
. Tightenthe boltsintosteps.
1st step: 8 N-m (5.8 lb ft)
znd step: 30"
10, Installcylinderheadassembly,referto CylinderHead¡nthis manual.
Pistonand ConnectingRod
P¡ston,ConnectingRod and Assoc¡ateParts
.^ | + ¿
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0t5Rw03
Legend
(1) CylinderHeadAssembly
(2) Cylinder Head Gasket
(3) Oil Pan Assembly
(4) Pan Support

(5) Oil Strainer
(6) BalanceUnitAssembly
(7) Piston and ConnectingRod Assembly
(8) PistonRing
(e) Piston Pin
(10) Piston
(11) ConnectingRod
(12) ConnectingRod Cap
Disassembly
1. Removecylinderheadassembly(1),referto CylinderHeadRemoval¡nthis manual.
2. Removecylinderheadgasket(2).
3. Removeoil pan assemblyand oil pan support(3), referto Oil Panand Oil PanSupportin this manual.
4. Removeoil strainer.
5. Removebalanceunitassembly.
6. Removeconnectingrod cap w¡thconnectingrod lower.
7. Removepistonand connectingrodassembly(7).
Notice: Beforeremovingpistonand connect¡ngrod assembly,measurc thrustclearance.
. Remove'anyridgeor carbonbuildup fromthe top end of the cylinder.
8. Removethe pistonrings(8) witha p¡stonringexpander.Arrangethe removedpistonringsin the
cylindernumberorder.
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9. Removethe pistonpin (9).
. Heatthe connectingrod andthe pistonpin withoil heater,when it temperatureis keepat
280'C-320'C.
. Pushthe pistonpin withbrassbar.
Notice: Keep the parts removedfrom each cylindersepante. All partsmust be reinstalled
in theh original positions.
10. Pisron(10).
11.Connecting rod(11).
(10)
P¡stons
Carefullycleanawayall the carbonadheringto the p¡stonheadandthe pistonringgrooves.
Notice: Never usea whe brush to clean the pistons.Damagewill result. Visuallycheck each pistonfor crack¡ng,
scoring,and other signsof excessivewear- ll any of the aboveconditionsare found,the pistonmustbe reptaced.
Piston R¡ngs(8)
Any wornor damagedpartdiscoveredduringengineoverhaulmustbe replacedwith a new one.
'1. Ringendgap measurement
. Insertlhe p¡stonringintothe bore.
Pushthe ringby the piston,at a rightangleto thewall,intothe po¡ntat whichthecylinderbore
diameteris the smallest.
. Measurethe ringend gap.
Compression Ring
1st ring
Standard: 0.30mm-0.50mm
(0.0118
in-0.0195
in)
2nd ring
Standard: 0.30mm-0.50mm
(0.0118
in-0.0195
in)
Oil ring
Standard: 0.40mm-l.40mm
(0.0156in-0.0546
in)
2 . Measurethe clearancebetweenthe pistonring grooveand the pistonringwith a feelergauge. lf the piston

ringgroove/ pistonringclearanceexceedsthe specifiedlimit,the pistonmust be replaced.
3. CompressionRing Clearance
Standard: 0.02 mm-0.04mm (0.0008in.-0.0016in)
015RW025
PistonPin (9)
Notice: Do not reusethe old pistonpin.
1. Use a micrometerto measurethe new pistonpin outsidediameterin both directionsat three different
positions.
2. Measurethe insidediameterof the connectingrod smallend. lf the fittinginterference
betweenthe small
end and pin does not conformto the specifiedvalue,the connectingrod mustbe replaced.
Standard : 0.02 mm-0.041mm (0.0008in-0.0016in)
\
I
3. Insertthe newpin intothe pistonand rotateit. lf the pin rotatessmoothlywithno backlash,the clearance
is normal.lf thereis backlashor roughness,measurelhe clearance.lf the clearanceexceedsthe
specifiedlimit,the pistonmustbe replaced.
Clearance
Standard: 0.011mm-0.014mm (0.0004in.-0.0005 in)
ConnectingBods (11)
1. Measurethe oil clearancebetweenthe connectingrodand the crankshaft.
. Removethe connect¡ng rod cap nutsand the rodcaps (12).
Arrangethe removedrod caps in the cyl¡ndernumberorder.
. Cleanthe rod bearingsand the crankshaftp¡ns.
. Carefullycheckthe rod bearings.lf evenone bearingis foundto be damagedor badlyworn,
the entirebearingassemblymustbe replacedas a set. Reinstallthe bearingsin the¡roriginal
positions.Applyplastigageto the crankpin.
. Reinstallthe rod caps(12)to theiroriginalpos¡t¡ons.
'lightenthe rodcap nuls.
lst step: 35 N-m (26 lb ft)
2nd step: 45"
3rdstep: 15"
Notice: Do not allow the crankshaftto rotate.
Removethe rod caos.
. Measurethe w¡dthof the plastigageand determinethe oil clearance.lfthe o¡lclearanceexceeds
the limit,replacethe rod bearingas a set.
Standard: 0.006mm-0.031mm (0.0002¡n-0.0012¡n)
L¡mil: 0.12mm (0.0047in)
. Clean the plastigagefrom the bearingsand the crankshaftpins.
CrankshaftGrindingDimensions mm (¡n)
(continued)
Productionand Service
Con-rodbearingjournaldia.
Standard size
(no color code) 48.970to 48.988(1.9098-1.9105)
Undersize0.25 (0.0097)
blue 48.720to 48.738(1.9001-1.9008)
0.5 (0.0195)
Undersize
white 48.470to 48.488(1.8903-1.891)
Con-rodbearingjournalwidth
Standard size
(no colorcode) 26.460to 26.580(1.0319-1.036)
0.25(0.0097)
Undersize
blue 26.460to 26.580(1.0319-1.036)
0.5 (0.0195)
Undersize
white 26.460to 26.580(1.0319-1.036)
Con-rodwidth 26.338to 26.390(1.0271-1.0292\
Reassembly
1. Installconneclingrod
2. Installpiston
3. Installpistonp¡n
. Applya thin coat of engineoil to the pistonpin. Tryto insertthe pistonpin intothe pistonpin
holewith normalfingerpressure.
Notice: Whenchangingpiston/ connectingrod comb¡naüons,do not changethe piston/ piston
pin comunafion and do not reuse the old pistonün.
. Attachthe pistonto the connectingrodwiththe pistonfront markandthe connectingrodfront
markon the sameside.
. Heatthe connectingrodsmallend to a suitabletemperature to ensuresmoothinstallation.
4. Installpistonringwiththe pistonring expander.
. NewpistonringswithTopuppermost- usecommercially availablepliers.
. Posit¡onring gaps:
1 - Compress¡on rings180"to eachotheras illustrated.
Offset oil controlrings25 to 50 mm/1 to 2 in. from gap of secondcompressionring.

A
--1¡-
-o-
015BWO6
. After¡nstallation,applyengineoilto the entirecircumference
of the pistonrings. Checkto see
that all the ringsrotatesmoothly.
5. Installpistonand connectingrod assembly.
. Insertthe bearingsintothe connectingrodsand caps. Applynew engineoil to the bearing
facesand nuts.
. fighten the connectingrod cap nutsin 3 steps:
lst step : 35 N-m (26 lb ft)
2nd steo: 45"
3rd steo: 15"
Notice: Do not awy engineoil to the bear¡ngback faces-
6. Oil gallery referto Crankshaftand MainBearingin this manual.
7. Oil strainerand O-ring.
8. Installbalanceunitassembly,referto BalanceUnitAssemblyin th¡smanual.
9. Installoil pan supportassembly,referto O¡l Panand Oil PanSupportin this manual.
10. Installcylinderheadgasket.
11. Installcylinderheadassembly.
. Referto CylinderHeadin this manual.
CylinderBlock
GylinderBlock and AssociatedParts
ffirH
Legend
(1) CylinderHead Assembly
(2) Oil PumpAssembly

(3) Oil Pan
(4) Oil Pan Support

(5) Oil Strainer
(6) BalanceUnitAssembly
(7) Piston and ConnectingRod Assembly
(8) Main BearingCap
(e) Crankshaft
( 10 ) CylinderBlock
Disassembly
1. Removecylinderheadassembly.
2. Removecylinderheadgasket.
3. Removeoil pan assembly.
4. Removeoil pan supporl
5. Removeo¡l strainer.
6. Removeoil pumpassembly.
7. Removebalanceunitassembly.
8. Removepistonand connectingrod assembly.
9. Removeflywheel.
10. Removerearoil seal retainerassembly.
11. Removema¡nbearingcap.
12. Removecrankshaft.
13. Removerylinderblock.
1. Removethe cylinderheadgasketand any other materialadheringto the upp€rsurtaceof the cylinder
block.Be very carefulnot to allowany materialto acc¡dentally drop intothe cylinderblock. Be very
carefulnot to scratchthe cylinderblock.
2. Carefullyremovethe oil pump,rearoil seal retainer,and crankcaseassemblyinstallaüon surfaceseal.
3. Wipethe cylinderblockclean.
4. Visuallyinspectthe cylinderblock. lf necessary,use a flaw detectorto performa dye penetrateand
hydraulic(or a¡rpressure)test. lf crackingor otherdamage¡sdiscovered,the cylinderblockmusteitherbe
repairedor replaced.
Flatness
1. Usinga straightedgeand feelergauge,checkthat the uppersurfaceof the cylinderblockis notwarped.
CAUTION!Be very careful not to allow any materialto accidentallydrop into the upper surfaceof
the cyl¡nderblock. Be very careful not to scratch the upper surface of the cylinder block.
2. The cylinderblockmustbe regroundor replacedif the warpageexceedsthe limit.
Warpage
Limit : 0.40 mm (0.0156in)
Maximum repairablelimit: 0.40 mm (0.0156in)
CylinderBore
Use a cylindergaugeto measurethe cylinderborediameterin boththe axialand thrustdirections.Each
measurement shouldbe madeat six points-
CAUTION!Be very careful not to allow any mater¡alto acc¡dentallydrop into the upper surlace of the
cylinder block, Be very careful not to scratch the upper surfaceofthe cyl¡nderblock.
lf the measurement exceedsthe specifiedlim¡t,the cylinderblockmustbe replaced.
D¡ameter
Grade 1 : 85.975mm€5.985 mm (3.3530¡n-3.3534in)
Grade 2 : 85.985mm-86.025mm (3.3534in-3.3550in)
Oversize: 0.5 mm (0.0195in)
Notice: For inlormationon pistondiameter,pleaserefer to the sectionlnspecüonof the Pistonand Connecting
Rod Assemblyin this manual.
Reassembly
1- Installcylinderblock.
2. lnstallcrankshaft.
. Installthe mainbearingsto thecylinderblockandthe mainbearingcaps.
. Be surethat they are positionedcorrectly.
. Applynew engineoil to the upperand lowermainbear¡ngfaces.
Notice: Do not apply engine oil to the bearingback faces.
. Carefullymountthe crankshaft.
. Applyengineoil to the thrustwasher.
3. Installrearoil seal.
. Coatlip of seal ringsthinlyw¡thprotectivegrease.
Installseal ring into cyli nderblock,use J-42616(1) and -42613
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015RW009
4. lnstallflywheel
. Thoroughlycleanand removethe oil from the threadsof crankshaft.
. Removethe oil from the crankshaftand flywheelmountingfaces.
. Mountthe flywheelon the crankshaftand then installthe washer.
. Use stopper (J-42618)to hold the crankshaft.
Preventfrom rotating.
f ighten the flywheelboltsin 3 steps:
2nd step: 30'
3rd step: 15'
Notice: Do not reuse the bolt.
t\
015RW010
5. Installpistonand connectingrod assembly.

. bearingsand the crankshaftpins.
Applyengineoil to the cylinderbores,the connecting.rod
Notice: Do not apply engine oil to the bearing back faces.
. Positionring gaps:
1 - Compressionrings 180' to each otheras illustrated(A).
2 - Offsetoil controlrings25 to 50 mm/1 to 2 in. from gap of secondcompressionring (B).

A
-------1¡-..-
6. Installbalanceunitassemblyand tightenthe boltsin 2 stepsin the ordershown:

lst step : 20 N-m (14 lb ft)
2nd step : 45'
7. Installo¡lpumpassembly, referto Oil Pumpin thismanual.
8. Installo¡lstrainer.
9. Installo¡lpansupport.
10. Installoil pan assembly.
. Completelyremoveall residualsealant,lubricantand mo¡sturefromthe sealingsurtaces.The
surfacesmustbe perfectlydry.
. Applya correctwidthbeadof sealant('lB-1207Cor its equivalent) to the contactsurfacesof the
crankcase.Theremustbe no gaps in the bead.
. The oil pan mustbe installedwithin5 minutesaftersealantapplication.
. T¡ghtenthe boltsand nutsto the specitiedtorquein 2 steps:
lst step : I N-m (5.8 lb ft)
2nd step : 30"
11. Installcylinderheadgasket.
12. Installcylinderheadassembly,referto CylinderHeadin this manual.
6A-86
CylinderHeadCover
cylinder Headcover and Associatedparts
0104w0a
Legend
lgnitionCable Cover
CylinderHead Cover
Removal
1. Removetwo boltsand removeigniüoncablecover(1) fromcylinderheadcover(3).
2. Disconnectignitioncableand removesparkplug (2).
3. Disconnectignitioncablefrom ignitionplug.
4' Disconnectcamshaftanglesensorharnessand crankshaftanglesensorharnessfrom
behindgenerator.
5. Removefour bolts and removethe crankshaftpulley.
#ñ
020RW014
6. Removetiming belt front cover.

7. Loosefixingbolt of timingbelt rear cover,then removethe camshaftanglesensor.
020RWj12
8. Removeten cylinderhead coverfixingboltsand removethe cylinderhead cover.

Installation
1. Installthe camshaftanglesensorand tightentimingrearcoverbolt.
2. Installthe cylinderhead coverand tightenboltsto the specifiedtorque.

3. Installthe timingbelt front coverthen tightenfixingboltsto the specifiedtorque.
4. Installthe crankshaftpulley,tightenfixingboltsto the specifiedtorque.
Torque:20 N-m(14lb ft)
021Rw014
5. Move drivebelt tensionerto looseside usingwrenchthen installthe drivebelt to normalposition.
0s3Rw001
6. Connectignitioncableto ignitionplug.
7. Installignitioncable cover to cylinderhead cover and tightentwo boltsto the specifiedtorque.
BalanceUnit Assembly
BalanceUnit AssemblyAssociatedParts
Legend
(1) Oil Pan
(2) Oil Pan Support
(3) Oil Strainer
(4) BalanceUnit Assembly
(5) Shim
Disassembly
1. Removethe oil pan.
2. Removethe oil pan support.
6A-90
MY99RodeoServiceManual
3. Removethe oil strainer(1) frorn pump and the oil baffle plate (2).
OSlRWON
Adjustment
1' Turn crankshaftin enginerotationaldirection
to alignmentmark (2) 1st cylinderTDc.
014RW066
2. In this crankshaftposition,the flattenedside (arrows)
of both balancershafts must face downwardand
must be on a horizontalline.
051RW010
3. screw measuringdeviceJ-43038-(3)with long knurled
bolt (1)into 1st balancershaft (intakeside)and
tighterhard-tightmeasuringarm (5) must poin-tin
9 o'clockdirectionshown in this illustration.
,f . -
Installdial gauge holderwith dial gauge(4) on cylinderblock.

1
\
\
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4. Placepre tensionedprobe(6) of gaugeon measur¡ng arm of measuringdeviceJ-43038.The probemust
be set preciselybetweenthe notchmarks,squareto the planesurface(7).
>n
7/¿ W,?va
I
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051RW006
5. Determinethe left and rightstopsby turningthe knurledbolt (2).

Set the dial of the gauge to zero.
Use the knurledbolt (2) to move the 2nd balancershaft (exhaustside) back and forth. Again-
simultaneouslyread off the tooth backlashfrom the gauge.
The permissibletooth backlashis: 0.02 mm to 0.06 mm (0.0008to 0.0024in).

1 ______-_^
1---
\
\ /
/\
'@
6. The toothbacklashmustbe measuredin 4 differentpositions- turnlhe crankshaftfurtherat the fasten¡ng

boltof the timingbelt drivegearby 45" in the enginerotationaldirectionunülthe measuringarm (2) is at
6 o'clock.
7. Then loosenthe knurledbolt (3)fix the measuringarm at g o'clockagainand repeatthe measurement.
051RW007
8. lf the valuedeterminedin one of the 4 measurementslies outsidethe tolerance0.02 mm to 0.06 mm

(0.0008to 0.0024in), the tooth backlashmust be adjusted.
9. Removebalanceunitfrom cylinderblocllcrankshaftbearingcaps and removewith balancerpiece. The
balancerpiece has a number(code),for easy assignment.The tooth backlashcan be adjustedby
usinga balancerpiecewith a differentthickness.
Code Thicknessof balancerpiece in mm
55 0.535 to 0.565
58 0.565 to 0.595
61 0.595 to 0.625
64 0.625 to 0.655
67 0.655 to 0.685
70 0.685 to 0.715
73 0.715 to 0.745
76 0.745 to 0.775
79 0.775 to 0.805
82 0.805 to 0.835
85 0.835 to 0.865
CAUTION!The next larger or smallerbalanceralters the tooth backlashby 0.02mm (0.000Sin). Example
of selection of balancerp¡ece:The installedbalancerpiece with the code 70 gave a tooth backlash oi
0.08 mm (0.0031in). lf a balancerpiece with the code 67 is now installed,the tooth backlashw¡ll be
approx. 0.05mm (0.0024¡n).
Notice: Only one balan@rpiece may be ¡nstalled.
Reassembly
1. Turncrankshaftin enginerotationaldirectionto alignmentmark(2) 1st cylinderTDC.
014RW066
6A-94 MY99RodeoServ¡ceManual
2. Turnbalancershaftsuntilthe flatteneds¡des(arrows)of bothbalancershaftsfacedownwardand are on a

horizontal
line.
3 . Installselectedbalancerpiece (2) with balancershaftunitto cylinderblocUcrankshaft

bearingcap - tighten
all fixingbolts to the specifiedtorque.
Torque:20 N-m (15 lb Ít)
4. Afterinstallingthe balancershaft unit,recheckthe toothbacklashand readjustif necessary.
CAUTION!lf the balancer shaft unit has to be replaced,use the thickest balancer piece with the
code 85 for the initial assembly - this guaranteestooth backlash in all conditions.
5. Installoil strainerto oil pump with new seal ring and insertfixingboltswith lockingagentto the specified
torque.
6. Installoil pan support.
. Adjustsurfacesof the cylinderblock and the oil pan support.
03,RW026
7. Installoil pan.
1st step: 8 N-m (5.8 lb ft)
2nd step: 30"
Main Dataand Specifications

TorqueSpecifications
Camshaft bracket,Timing gear camshaft side, Cylinder head
1ststep 2nd step Srdstep 4th step
25N.m(18lb ft) 90" 90" 90"
r-]
lo
t,.f:
-l L,/
o/
o
50N.m{36 lb ft)
Timing gear crankshaft(centerbolt), Timing belt cover front, Timing b€lt cover rear,T¡m¡ngbelt tensioner,
Camshaftangle sensor
6N.m(4.4lb ft) -& I
:\[
*;6-m--
"*o@:
l25N.m(1Bhrtü-..\#ffi1
- < Ar @
\/
@P'tlj
MY99RodeoServiceManual 6A-97
Crankshaftmain bearing,Oil pan support,Oil pan, Balanceunit assembly,ConnrodC"p, Oil pump,

Oil strainer
tu
Í¡\
\+ 20N.m(14lb tt)
F,-P,
H II
ñNi
8N.m(5.8lb ft)
Spark plug, Throttle body, EGRvalveadaptorassembly,Bypass hous¡ngassembly,Thermostatassembly,

inlet manifold assembly,Exhaustman¡toldassembly,heat shield, lgnit¡oncable cover
15N. m {1 1l b f ü
8N.m(6.9lb ft)
3N.m(2 lb ft)
ffi
@"#fu
rc,&{ñ
Engine mount
F\'
ñ
$
n--¡\t
\i lll'si
hY
SpecialTools
TOOL NO.
ILLUSTRATION
TOOLNAME
J-42613
lnstaller;Rear crankshaftseal ring
J-42609
Remover/lnstaller:
Crankshaftcarrierseal
J-8062
Compressor;Valve spring
(Use with J-3289-20base)
¡--- ''r.'
..r .-, |
i-=- .z' ,\ i t,.
t:,
,' ""-l i \
L .- r . i iI
r l .I
LJ - l - l
i J-43037
/ i i i(-,'i Lockingtoolcamshaftgear
.t_i.:. i i
¡ ._,' 1i
.,r_.J .l | ,
LL--
J-42616
Installer:Rear crankshaftseal
J-42618
Lockingdevice; Flywheel
J-42619
Adapter; Valve spring
MY99 Rodeo Service Manual 6A
C J-42622
Installersleeve;Valvestemseal
J-42623
Socketwrench;Cylinderheadbolt
J-42620
Holdingwrench;Drivengearfix

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MY99 Rodeo Service Manual

cAuTloN!Always use the correctfastenerin the proper location.Whenyou replacea fastener,

' Any t¡methe intakea¡rduct or air cleaneris removed,the intakeopeningshouldbe covered.Thiswill

Condition PossibleCause Correction

Condition PossibleCause Correction

2. lgnitionTrouble- Start¡ngMotorTurnsOverBut EngineDoesNot Start

Condition PossibleCause Correction

Fuel not reachingfuel injector(s) Refer to item 3 (Troublein

Valvetiming incorrect Adjust

Poor connectionsin engine Correct

PowertrainControlModulecable Corrector replace

3. Troubleln Fuel System

Fuel filter clogged Replacefilter

Fuel pipe clogged Clean or replace

Fuel pump defective Replace

Fuelpumpcircuitopen Corrector replace

Condition PossibleCause Correction

Condition PossibleCause Correction

Cylinderor pistonringsworn Overhaulengine

Throttleshuttingoff incomplete Corrector replace

Fuel injectorcircuitsopen Correct or replace

Fuel injectorsdamaged Replace

Condition PossibleCause Correction

ManifoldAbsolute Pressure Correct or replace

KS Modulecircuitsopenor ground Corrector replace

VehicleSpeed Sensorcircuit Corrector replace

VehicleSpeed Sensor defective Replace

ExhaustGas Recirculation Replace

Canisterpurge solenoid Correct

Canisterpurge solenoiddefective Replace

Troublein ignitionsystem Refer to Hard Start

Condition PossibleCause Correction

Spark plugs fouling Clean or installhottertype plug

ManifoldAbsolutePressure(MAP) Corrector replace

EngineCoolantTemperature Corrector replace

Hesitationon acceleration Throttle Position Sensor Replacethrottlevalve assembly

ThrottlePositionSensorcircuit Corrector replace

ManifoldAbsolutePressure(MAP) Corrector replace

MAP Sensor defective Replace

lntake Air Temperature(lAT) Correct or replace

KnockSensor(KS)Circuit Corrector replace

KS Modulecircuitsopenor shorted Corrector replace

KS Module defective Replace

IAT Sensor defective Replace

Hesitationat high speeds Fueltank strainerclogged Clean or replace

Fuel pipe clogged Clean or replace

Fuel filter clogged Replace

Defectivefuel pump system Check and replace

Fuel PressureControl Valve Replace

Hesitationat high speeds Powersupplyor groundcircuitfor Check and corrector replace

Cableof MultiportFuel Injection Corrector replace

Hesitationat high speeds EngineControl Moduledefective Replace

ThrottlePositionSensorcircuit Corrector replace

EngineCoolantTemperature Correct or replace

Condition PossibleCause Correction

MAP Sensorcable open or shorted Corrector replace

MAP Sensor defective Replace

IATSensorcircuitopenor shorted Corrector replace