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ISUZU C223 Turbo W Shop Manual

ISUZU C223 Turbo W Shop Manual

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SUPPLEMENT

ISUZU MOTORS LIMITED

':

g G -CAMERON & SONS PTY.
BOX 116 P.O. oRANGE 2800

rrl

SECTION INDEX
SECTION

NAME
GENERAL

ISUZU

1

INFORMATION

WORKSHOP MANUAL
DIESEL ENGINE

2 3

ENGINE ASSEMBLY

LUBRICATING SYSTEM

C223 TURBO MODEL SUPPLEMENT
*

*4
5

COOLING SYSTEM

FOREWORD
FUEL SYSTEM

This manual describes the different points on the engine components of the C223 TURBO model to the c223.
The components not dealt with in this manual, refer to the C223 WORKSHOP MANUAL rc223-WE141l,. This manual includes special notes, important points, service data, precautions, etc. that are needed for the

si

-.\$

s
ir

6

INTAKE AND EXHAUST SYSTEM

maintenance, adjustments, service, removal and installation of components of the models titled.

*7
*8

AUXILIARIES

All information, illustrations and specificatioins contained in this manual are based on the latest product information available at the time of publication.

SPECIAL TOOL LIST

The right is reserved to make changes at any time

without notice.
Arrangement of the material is shown by the table of contents on the right-hand side of this page. Black spot on the first page of each section can be seen on the edge of the book below section title. A more detailed table of contents precedes each section.

I

CONVERSION TABLE

This manual applies
models.

1984 year and later included Refer to C223-WE-141.

GENERAL INFORMATION 1_1

sEcTloN

1

GENERAL INFORMATION
INDEX

CoNTENTS Generat repairinstructions.... How to use this manual Maindataandspecification Torquespecifications Servicing Recommended lubricants .. Engineoil viscositychart
Adhesive for repair

PAGE

....1. . . . 1- 2 .......1- 5 ..'.'. 1- 7 '.....1- I . 1-12 ...1-13
1

GENERAL REPAIR INSTRUCTIONS
1. 2. 3. 4. 5. 6. 7. 8. 9.
For assurance of safety, park the vehicle on level ground and brace the front or rear wheels when lifting the vehicle. Raise the vehicle with a jack set against the axle or frame and perform service operation after supporting the vehicle

on chassis stands. Before performing service operation, disconnect grounding cable from the battery to reduce the chance of cable damage and burning due to short-circuiting. Use a cover on body, seats and floor to protect them against damage and contamination.
Brake fluid and anti-freeze solution must be handled with reasonable care as they can cause paint damage'

The use of proper tools and special tools where specified, is important to efficient and reliable service operation.
Use genuine lsuzu parts.

Used cotter pins, gaskets, O-rings, oil seals, lock washers and self lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

To facilitate proper and smooth reassembly operation. keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important as they vary in hardness and design depending on position

of installation.

) 7. 13. For assurance of safety. 6. 3. The "standard" means the assembly standard and standard range within which the parts are considered serviceable. ln this manual.ts or equipments. 14. hoses or 15.1 -2 GENERAL INFORMATION the parts before inspection or reassembly. Find the applicable section by refering to the index. notice is inserted stating. other parts from any unit under air pressure. Lubricate rotating and sliding faces of the parts with oil or grease before installation. is omitted and important operation such as adjustments. Find the Wpe of unit or equipment to be serviced by referring to the "Application chart" or "ldentification of unit or equipment" included in this section. When necessary. description of self-explanatory items such as removal of individual parts from unit to be removed. Carefully observe all specifications for bolt and nut torques. the components and parts are printed in singular form. "Refer to manual for other units or equipments". Each section includes removal and installation. 12. using compressed air to make certain 10. . inspection and repair and reassembly. 4. The service standard is indicated in terms of "Standard" and "Limit". HOW TO USE THIS MANUAL 1.4' 2. etc. When service operation is completed. use a sealer on gaskets to prevent leakage. make a final check to be sure service has been done properly. ln removal and installation section. Also clean oil ports. 1. This manual includes "General information" section in which service data. disassembly. are dealt with mainly. 5. maintenance items and specifications with torques are included. "Limit" indicates the limit value (Correction or replacement is necessary when measurement is beyond this limit. etc. . When the same service operation applies to more than one un. always release air pressure solely from the air tanks before disconnecting pipes. Clean 1 they are free from restrictions. torque specifications.

l6va 49. F.12 are "Note" indicating models applicable. ldla th. availability and content of repair kits.nt blll. lnput rh.@t output rhaft. ipri..nd cat 421. ldl. High .hift to. Front drir.smbly 16. High ard low thift lork ldk wit€ 422.0. etc.lt oil $d Name of parts listed in sequence of service operation. 8. Each unit or part within frame is to be considered as "minor component".lt baaring 4. High.athar lnpul Front output lhatt llanga. illurtration b b. Front driy. --l_" Removal of the parts without number (excluding bolts.k l@k bolt I l.d ld.ne pi.h. a I I rt25 2A Parts to be removed or installed as unit.ft @vd 24. 14. Hieh md low shift rod ^18. al.. th. 3 . washers. 5. Shitt lork . lnput rhatt oil sal aA).rsl ioint A indicates important operation.hittlork fialt univ. 25.rv! ^17.h.d on th. ldl.k lmk bolt lnpd 3hafr b.c.!. The number represents sequence of service operation. gaskets. Front driv. eppliQble to sll modclr €rcluding 6 x 4 * parts contained in repair kit. MA'OR COMPONENT Thi. $@bu.r6nt b. 6 r 6 and 4 r 4 modolr..19.nd dcvc m.hift to.r ll0..GENERAL INFORMATION 1-3 8. lnpd.t. . instructions are given in "lnspection and repair" * __l indicates repair kit availability.tt rl. Hish. lnput shah di. rpring lnd Front d. lnput rhaft ^13.iFat d as No.ll.ring lnput thalt $afine 13.nd nut 15.nd low.ivc. and nut ^31.tt. rhilt rod d. -"-}a. Each service operation section begins with disassembled view of unit or equipment which is useful to find components.8.t.nd coll. nrar covar arsmbly ^23. Tha ltaF of srvice otsralaon d. . Front outpul rh.) is unnecess- ary unless when replacement is needed. Front output lhalt dirt. Where parts replacement requires specific note.hrft .^ -----:l All units or parts within frame are to be considered as "major component". are Details of service operation described in the paragraph "lmportant operations". cotter pins.hitt rod . 28. . Rmfi5ly tt p. Front output ah. Front outpt rhaft 6. Front driva lhifr tork . Front output 3h. .lt 3nrpring 2.. 29.lt yok. idl. service procedure. 7. Shitt iort.nd rld.. etc. ^12.tl thim nai ^27.nd low thih fo.n6 pi.hift rod d.6 26.k ldk wi. nuts.

9.oool H'9h 6. "A" V @ lmportant operrtions l lnFlrh6ftb€rring 3.1-4 GENERAL INFORMATION 9. Front outpul ftrft b.ontdrivcrhih rod.8522. F?ont dtpul !h.0 _r\ __r-t\_____r_.d low rh't ro. L- "i-l High Fronl driv. carefullv nored.rring lnstaller. The drawing illustrates how the tool is 8. . lmportant note.lt tlolvr - used. The shitt 17.rd coll. .\ Item shown in the illustration marked with "4" and Special tools are identified with tool name and/or part number. Remove lnstall Disassemble Reassemble E E E ffi Adjustment Clean 6 V q @ Pay close attention - imPortant Tighten to specified torque Use special tool(s) (lsuzu's tool(s)) Use special tool(s) (parts manufacturer's tool(s)) Lubricate with oil Lubricate with grease E H Align the marks Correct direction lnspect Take measurement tr @ tr tr @[ 11. ln this manual. etc. lork groove side taces downward.que ltg ml 4 5 5 10. the following symbols are used to indicate the type of service operations to be performed. d Front dra !h. The section following illustration(s) deals with important service steps marked with This section also includes "notes". tr . The special tools with part number preceded by the alphabet "J" are manufactured by Kent-Moore Corporation.0O4O.rd low rhifl rod The pans rnclude thift rodr lor high and low tpeed relection and for Direction ot inilallarion of the pans thould b€ The symbol indicates the step of service to be followed. 18. F. 9. lnput rheft rloor. "service data". ihilt lork lock bolt lrd low shiti lork lock bll To. Service data and specif ications are listed in table. "use of special tools". These tools are also available at local outlet of Kent-Moore Corporation throughout the world. . High.r I rdr 1r@nr L .lt rcd ooj Refer to the following paragraph for meaning of each symbol.

C.C. static) (mm) (kg) 1-3-4-2 6o (for gear drive) 1O" (for belt drive) High-speed dieselfuel (SAE No.voltage Generator Voltage Voltage Starter valve 31 (at 2OO rpm) 725 -775 (in cold) 0.O lmpeller tyPe pellet type (with jiggle valve) Wax Paper element tYPe v) capacity NS70 v-A) V. of cylinders . 741 x546 x7'l 6 A.T.O .B.T.12 12-40 12 .Bore x (mm) (cc) 4-88x92 2238 21 :1 Approx.D.) 51' (B. overhead valve type Swirl chamber type Combined with cylinder block (Liner less) Gear drive/Belt drive Compression ring2.C.4 1 1" (B.T.D. of piston rings stroke Total piston displacement No.C. 4-cycle in-line.B.) 9" h.D.pprox.KW) output .) Pressurized circulation Gear tYPe Paper element partial-flow tYPe With oiling jets (titers) 6.D.5 Water-cooled Pressurized circulation (liters) 9.2.oil ring 1 Combustion chamber type Cylinder liner type Timing gear system No.D.22O Compression ratio Engine dimensions : lengthxwidthxheight Engine weight (dry) Fuel injection order Fuel injection timing (B. 2) Type of fuel used Fuelfilter type lnjection pump type Governor type lnjection nozzle type Fuel injection pressure Cartridge type Bosch distributor VE type with boost compensator (tg/cm') (kg/cm'z) (rpm) (mm) Mechanicalvariable speed (half all speed) Throttle type 135 Compression pressure ldle speed lntake and exhaust valve clearance lntake open at closed at Exhaust valve open at closed at Lubrication method Oil pump type Oil filter type Piston cooling method Lubricating oil capacity Oil cooler type Cooling method Cooling water capacity Water pump type Thermostat type Air cleaner type Battery type .C.GENERAL INFORMATION 1 -5 MAIN DATA AND SPECIFICATIONS Engine model Items Engine type c2237 Water-cooled.) 49'(A.

OO0 engine rpm (mmHg) .60 1.85 Maximum pressure ratio Wastgate controlcariblation (mmHg) pressure 690 :t 20 28O or more at4. outward-flow Maximumspeed".) 6.OOO (kg/min.I€ ENEfiAT. Maximumair delivery Boost (rpm) 140. inward-flow Radial.' I NFO RMATION Engine model Items Turbocharger type turbine type compressor type c2237 TBO209 Radial.

.4 35.2 -'t'r.9.J 43.4 6.O 16 x 1.7 The asterisk' indicates that the bolts arb used for female-thieadgd part6'thbt are made of soft materials such as casting. io 1 ri I.5 20. .2 ' .5 116 x 2.9 7.5'-.25 '1O x 1.0 .O 8 x 1. 56.J..1 - 2.8 .8.8 7.6 - 55 37.:1.r'3.5 - 48.' - 0. 0..{.6 10.1.0-55. .iGEff'EftAftel mqmffim@fl .:il 9.6 .9 84. :.5 22\ 1.2 : 24.5 ':1.2 13.3 5.5 64.9 27.0 11.3 43.6 Q\.:ri r\.5 r't '12 x 1.0 0.4 - o.8 13.8 .5 23.8 29.5j. 9.6 6.6 -# {t# .4 13.9 r 6.0 15.5 3.3 15.0 l 6 x 1. etc.3 .8 2.3 : Jo.9 ./.1 3.72.4 _j+-"F'.3.5*- .8 19.- 10.4 7.5 'z :i - 41.' 32.4.fl.0 : 19.7 2.i" "".5 f5.4 16. Bolt identif ication Bolt diameter x pitch (mm) 4T " (Low carbon steel) l.7 -: .8 .t E 17.!1-O_1.i* t'l ! x--1.Q 3.6 25.25 10 x 1.r" \8'x \O 1.7 1.2 .:. 8.3 36.75 14 x 1.g:" 2.6 1'4.3 10.e t !+tr-<'* 11 - 11.€t-{7 TOROU E SPEGIFICATIO NS' STAilIDARD BOLTS :ihe tor{ue values given in the foliowing table shouid be bpplied where a particu-lar tbrque is n-oi ipecified. 7T (High carbon steel) 9T (Alloy steel) .8 r.fr '12 x 1.3 24.9 16.2 - .31. il : t'a_: -il .*.:. (kg-m).6 10.A . "".4.O $.$.1 6.7 7.5 '14 x 2. .8 1.J 1.7 3. i: -S.6 :42.9 .2 .s .2 23.

2116-231 ?C 16-18(116-130) .8-2.411T171 ffi1-@ ----4 Y -"'t: __-tr.1 -8 GENERAL INFORMATION MAJOR PARTS FIXING BOLTS Cylinder head and injection pump (kg-m) 1. 2.8(1F13) 1.O----H.2-3.3-1.:--':'.

(See the illustrationl. INJECTION TIMING Turn the crankshaft in normal direction of rotation. and take the reading of the dial indicator when the timing mark on the crankshaft pulley is in alignment with the pointer. to the specified angle in Angle I I (t Apply bisulfide molybdenum grease to thread and contact surface when using used bolt. (mm) Standard reading 0. Torque 'i€ffi3:434':): -ffi-rio=a ffi @ t st step (snug torque) Tighten the cylinder head bolts sequence above.GENERAL INFORMATION 1 _9 SERVICING CYLINDER HEAD Tighten the cylinder head bolts in sequence as shown in the f igure.5 6o (for gear drive) 1Oo (for belt drive) .

lnstall boost pressure gauge. Take measurement with specified engine speed at no load. . Disconnect boost hose at injection pump side. 3.1 -1O GENERAL INFORMATION Timing belt train TURBOCHARGER 1. Check turbocharger mounting or connection for leakage or loose. Check boost hoses for loose connection or leakage. 2.

GENERAL INFORMATION Check oil line for leakage restriction or damage. 1 -11 .

! il j 1i1. . ii.1 ANTI-FREEZE ESSO RAD MOBIL PERMAZONE SHELLZONE SHELL GLYCOSHELL PLUS SHELLSAFE TEXACO ANTI-FREEZE COOLANT TEXACO STARTEX ANTI-FREEZE COOLANT TOTAL ANTIGEL UNION YEAR AROUND ANTI-FREEZE AND COOLANT .1 SHELL RIMULA CT OIL SHELL RIMULA X OIL SHELL MYRINA OIL : : lil il .irti: :i.11 'Jl ... :.' il' . lsuzu genuine lubricants LUBRICANT CD grade MAKE AND BRAND * BESCO S-3 ENGINE OIL BP VANELLUS C3 BP VANELLUS C3 MULTIGRADE CHEVRON DELO 4OO MOTOR OIL CHEVRON DELO 3OO MOTOR OIL CASTROL or DEUSOL CRD CASTROL or DEUSOL CRF CASTROL or DEUSOL RX SUPER CALTEX RPM DELO 4OO OIL CALTEX RPM DELO 3OO OIL ESSOLUBE D-3 ENIAGIP F.1 -12 GENERAL INFORMATION RECOM MENDED LUBRICANTS * Mark ..* SUNFLEET SUPER C SUNFLEET DIESELUBE SUNFLEET DIESELUBE XD TEXACO URSA OIL SUPER TEXACO URSA OIL LA-3 TOTAL RUBIA S TOTAL RUBIA TM UNION GUARDOL MOTOR OIL * ISUZU ANTI-FREEZE PT BP ANTIFROST Engine cooling system Permanent type antifreeze solution CALTEX AF COOLANT CASTROL ANTI-FREEZE CHEVRON ATLAS PERMA-GUARD ANTI-FREEZE AND COOLANT ENI AGIP F.1 DIESEL SIGMA Engine Diesel engine oil CD grade MOBIL MOBIL MOBIL MOBIL DELVAC 12OO SERIES DELVAC 13OO SERIES DELVAC SUPER DELVAC SHC h .ir t.

1 5W-50.) Loctite Primer N Belco Bond No. 5 rL-242 rL-262 TL-290 Locquic primer grade TB-1 TB-1 TB-1 TB-1 TB. 1 237 rKE41 RTV .TB-1521C ffhree Bond) . 22S Seal End No.242 DB Bond Black Sealer DB Bond Yellow Sealer DB Bond Clean Sealer 102 521 -B 741 Seal End Diabond Herme Seal Shinetsu Kagaku T8-2302 . 4 Belco Bond No.20W-40.TB-1521 (Three Bond) *Three Bond 200 (Three Bond) -Super Three Bond No.1 1 1 N 04 05 Three Bond Belco Bond 2Ol Three Cement Super Three Cement Sealock No.20W-50 ADHESIVE FOR REPAIR MAKE ISUZU Genuine parts or Recommended Brand name or Number Remarks Loctite Loctite 242 (Loctite Nutlock) Loctite 262 (Loctite Studlock) Loctite 290 (Loctie A.ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE Ambient 'l -30'C TemperatureJ( -20oF ) (80"F) {90"F sAE 10W-40 sAE 1 5W-40. 1OO0 Seal End No. 2O ffhree Bond) 'silicone Form-A-Gasket No. rHerme Seal No.TB-1102 (Three Bond) 'TB-1104 (Three Bond) .A. 6 (Loctite) ' mark means that the product is equivalent to Three Bond make or Loctite make.

n lnspection and ::.ENGINE ASSEMBLY 2_1 SECTION 2 ENGINE ASSEMBLY INDEX :::::::"1. repair ... 2-2 I GENERAL DESCRIPTION . ...

2188in.) o o C lnsert the piston ring into bore and push it in. 114(4.050 - o.2-2 ENGINE ASSEMBLY INSPECTION AND REPAIR tr @ Piston pin Visually inspect for damage. Piston ring gap: 1st.1 15 0.185 o. (mm) Piston Clearance between piston ring and ring grove Standard Limit 1st compression ring 2nd compression ring Oilring o. Outside diameter (mm) Standard Limit 29.4 .070 o.100 Piston ring Remove deposit of carbon from piston rings and check for wear and damage.97 at several points Fitting interference between piston pin and piston pin hole.030 - 0.2 - o. wear or other abnormal conditions.0 Measure ference. at a right angle to the wall.155 0. 28. 2nd compression 3 .120 0. deep enough to reach the point where the cylinder bore diameter is smallest then measure the ring gap.085 0.

in.c5s5. (See the illustatiod.ENGINE ASSEMBLY 16.l:mq figure. gJry-%:g Torque Tighten the cylinder head bolts sequence above. to the specified angle in Angle Apply bisulfide molybdenum grease to thread and contact surface when using used bolt. Cylinder head assembly 2-3 Tighten the cylinder head bolts in sequence as shown in the . .

.TUBRICATING SYSTEM 3-1 sEcTloN 3 LUBRICATING SYSTEM INDEX CONTENTS General description PAGE .5k9/cm2 r- Oil pan .. 3-1 GENERAL DESCRIPTION fl =:: Oil filter and cooler assembly Oil pres3ure switch Valve opening pressure I llr-r Fitter canridqe 3.

5-1 . .sEcrloN 5 FUEL SYSTEM INDEX PAGE General description lnjectionpumpdata.. .-5-2 GENERAL DESCRIPTION .

8941 32 .K.3580 .5-2 FUEL SYSTEM INJECTION PUMP DATA INJECTION VOLUME ADJUSTMENT TEST CONDITIONS lnjection nozzle I D.No. use the correct data following the injection pump identification number.1 020. P. 1 047 40-1 1 30. 8941 7 1 -85201 1 047 40 . MAKER% ASS'Y N0.PUMP ASS'Y N0.C. 6mm lnjection line Transfer pump pressure Test diesel fuel Testing oil temperature ldentification number i - Length 84Omm O.K.EF8S1 1/9A I l5Okg/cm2 lnner dia.2kg/cmz lso standard test oil (lso 41 1 3) sAE standard test oil (sAE 967.C. 1 O5 78O-0000 Bosch type No.K.No. 1 04740-1050. 2mm x Outer dia. INJ. 1 047 40 -1 1 40 I ' r' IDENTIFICATIONS PLATE AND NUMBER When adjusting injection volume. (8941 7 1 -85 1 0.DN'l 2SD12T njection nozzle holder njection starting pressure D. 1 047 40-1 1 20. P.K.d) 45 - 50'C t E p I I ? 1047 40-1 030. 1 O5 780-2080 Bosch type No.

1 1250 1 700 21 50 2.3- 12-15 mm deg.8 40.6-5.4 ldle speed regulation 1. Settings Pump Speed (rpm) Settings 2.6-2.0 6.0 2000 7.2-11.1 -42.0 mm 2.8-40.O 2.0-6.6 2150 6.5.3 Fuel deliveries 3.1.2 1.5 9.7 .4-42. . 60 9.9-46.2 2.20l Test diesel fuel : SAE standard test diesel fuel SAE J967d (or ISO 41 13) 1.9-8.2 Supply pump pressure Full load delivery without charge-air pressure Full-load deliver with charge-air pressure 1250 1250 4.O 2.1 mm kg/cm2 ccl1 0O0st o o 1250 375 100 1.4 37.8-49.894171-a5.6 Full-load speed regulation 1. cut-in voltage test voltage : : 8V 1 2V -14V .O ccl1 OOOst ccl1 OOOst 2.2 .2 250 1250 5.8 2550 45.8-84.7 3.9 1 1 ccll0O0st ccl1 OOOst 590-610 0 4.1 44.7 Load Timer Adjustment 1.4-26.9-25.3 Max.3-37.6-5.7 Charge-air press (mmHg) Difference in delivery (cc) 1.4-46. 9.7 Overflow delivery N:rpm ccl1 0s 1 000 40.4 5.2 4.6 21 Switch-off ldle stop Partial load 9.27 deg.FUEL SYSTEM 5-3 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM ldentification number: 1O474O-1O3O.4 Solenoid max.O 19.4 31. 104740-151O. Pump Speed (rpm) Fuel delivery ccl1 OOOsts Charge-air Dimensions Speed control lever End stop Desig- press.0 mm 37 .O ccl1000st o ccll OOOst 590-610 7.1 Timing device travel 1. 7.5 Start 1.3 44.4-3. 13.4 34.3.47 deg.3.9 32. 3.3 Min.5 .9 1.1-6.4-36.0 -3. Test Specifications Timing device Supply pump 2.4 | for assembly and I adjustment (mm) 3.4-7.6-3.3 . (mmHg) nation 2800 2550 2175 2000 1250 1250 1 150 900 600 Max. (894171-851O.

Pump speed (rpml 850 1250 Pump speed {rpml .

check the revolution and make sure no fuel leakage from the overflow of C.2 19.5.8 2. Settings Pump Speed (rpm) Settings Charge-air press (mmHg) 1.8-48.9 4.O 500.3 Fuel deliveries 3.4 ldle speed regulation 1 .47 deg.6 mm kg/cm2 ccl1 OOOst o o .27 deg. Pump Speed (rpm) Dimensions Speed control lever End stop Fuel delivery ccl1 OOOsts Charge-air Desig- press.1O474O-112O.2 2.700 Cancel speed ccllOOOst ccl1 OOOst Test Specifications Timing device Supply pump Overflow delivery 2.7 3. 1 Max.7 -9.2 Supply pump pressure Full load delivery without charge-air pressure 1250 1250 3.4 47.0 mm 37 .6-2. cut-in voltage test voltage : : 8V 1 2V -14V Upon canceling of C.4-4. Test Oil : SAE J967d or ISO 41 13 E .7 CSD Adjustment 1.1 46.4 2000 6.3-45.6 34.1-6.7 7.D.3- 12-15 mm deg.3 .5 Start 1.5-51.O mm Observations: 2.4 38.4 5. (mmHg) nation | I for assembly and adjustment (mm) 2800 2550 2175 2000 1250 1250 1 150 900 600 Max.8 1250 4.5.3.6 Full-load speed regulation 1.D.8-6.9 1.1 Timing device travel 1.6-5.8-84.0 1 2150 8.4-26.3.FUEL SYSTEM 5-5 INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM ldentification number : 1O474O-1O21.O ccll O00st ccllOOOst o ccll OOOst 590-610 7.5 42.4-3.3 34.5 .O 3.7 3.1-39. 21 9. 60 9. 9.4-43. 2550 47.2 700 5.1 -44.3 Min.7 .3-2. 1O474O-1140 Test diesel fuel : SAE standard test diesel fuel SAE J967d (or ISO 41131 Difference in delivery (cc) 1.1.7 .3.0 Full-load deliver with charge-air pressure 1250 375 100 1.1-39.2-11.S.S.9-25.7 N:rpm ccl1 Os 1 000 40.7 -41.O 2.3 Switch-off ldle stop CSD Adjustment . 36.1 2.8 9.7mm Cancel speed Partial load 2.9 1 1 ccll OOOst 590-610 0 4.5-3.2 1250 3. 104740-1130.O 250 1.4 Solenoid max.

Pump speed (rpm) TIMING DEVICE DIAGRAM .

. 6_g . 6_g Positive crankcase ventilation . ... .. front .. 6_7 (PCV) ..INTAI(E AND EXHAUST SYSTEM 6-1 sEciloN 6 INTAKE AND EXHAUST SYSTEM INDEX CONTENTS General description PAGE 6-2 6-3 .... 6_3 lntake and exhaust system Turbocharger .. Emission control system Exhaust pipe .

t.GENERAL DESCRIPTION From air cleaner PGV hose s ffiE ir. '"iir lnta + €-r +-- Blowdy Fresh air gns oil .

Exhaust manifold and turbocharger asm. Rubber hoses Connecting hose and inlet pipe asm. lntake manifold 9. delivery Oilpipe . 4.INTAKE AND EXHAUST SYSTEM 6-3 INTAKE AND EXHAUST SYSTEM TURBOCHARGER REMOVAL gi $ w Removal steps 1. Air cleaner and air duct Oilpipe. Connecting hose 8. 3. Exhaust pipe 11. Turbocharger . 10. 2. return lnlet pipe 7. 6. 5.

distortion and proper sealing.) 0.2 (0. F.. Air cleaner Check air cleaner element for distortion and damage..0079) 'l! ii .0197) Turbocharger Refer to the manual of the manufacture for inspection details Check items. I 'ii Exhaust manifold Check cylinder head fitting face of the manifold for distortioni 0.t ' i. Correct ot lace as necessary... Air cleaner element should be replaced at specified intervals more often when elemqnt is subject to dusty or severe c tions. air body for cracks.5 (o.6-4 INTAKE AND EXHAUST SYSTEM INSPECTION AND REPAIR Make necessary correction or parts replacement if wear.i : -r i !.lt.-. o Oil leakage o Bearing stick o Wheel interference o Shaft axial play o Shaft radial play -"-. . damage or any other abnormal condition are found t inspection.""-' .i r mm(in. ll:. lntake manifold Check cylinder head fitting face of the intake manifold for dis tion. The element should be replaced immediately if found be damaged or fouled..

lbs.lbs.) 2. Discard the used nuts and use new nuts whenever removed.6 @ oit pipe @ Cap nut 0. tion.5 - 5.8 1.5 (33 - 40) g Sa g=4 8. Tighten the nuts to specification i I j 3. return ks-m(ft.) 4.6 ( 6 - 12t . Oil pipe . Exhaust manifold and turbocharger lntake manifold i lnstall the manifolds and tighten the bolts and nuts to specifica- iI 7. 4. Oil pipe . delivery kg-m(ft. 2.6-6 INTAKE AND EXHAUST SYSTEM lmportant operation 1.4 112 _ "t7t Torque O Adaptor 1. Turbochager Exhaust pipe Install the turbocharger to the exhaust manifold and the pipe to the turbocharger.

5.'AL AND rNsrALLAroN Removal steps lnstallation steps 1. 4.INTAKE AND EXHAUST SYSTEM 6-7 EXHAUST PIPE .lnstallation 2. Gasket . 3. silencer lmportant operation . 6. 2. Nut . silencer Gasket Pipe assembly . hanger Clamp. 4. Use a new gasket when installing the exhaust pipe front . front 1. FRONT tr E REM. lock exhaust pipe to pipe Clamp. 6. hanger Clamp. 3. front Gasket Nut . Pipe assembly . lock exhaust pipe to pipe Clamp. 5. engine side Clamp. engine side Clamp. a 2.

4. REAR trE :. 2. rear Clamp . follow the removal procedures in reverse order. silencer . Clamp . 3.6-8 INTAKE AND EXHAUST SYSTEM EXHAUST SILENSER AND PIPE . front Silencer . rear Hanger Pipe assembly . 1. silencer .li REMOVAL AND INSTALLATION Removalsteps lnstallation steps To install. 5.

replace the PCV valve assembly. damage or any other abnormal conditions are found through inspection.INTAKE AND EXHAUST SYSTEM 6-9 EMISSION CONTROL SYSTEM POSIT]VE CRANKCASE VENTILATION (PCVI From air cleaner PCV Oil separator hose PCV valve assembly + lnbke pipe PCV valve Breather hose Turbo drarger -+* + Oil drain hose Check ualve Intake manifold + +=f +_- Blow{y Fresh air gas Oil pan oil INSPECTION AND REPAIR Make necessary correction or parts replacement if wear. . PCV valve assembly Check the diaphragm valve for damage. and adhesion to seating surface. and the oil separator element for wear if any abnormal condition are found.

t' lil I I Rubber hose Check the rubber hoses for evidence damage. of deterioration and . lf air flows in the wrong direcvalve is plugged.6-10 INTAKE AND EXHAUST SYSTEM Check valve Check the check valve function.. replace the check valve. tion or if i ".

1984 44-O2K-4 .I t l ! q223T-WE-441 You are requested to order this manual using manual number shown above. lssued by ISUZU MOTORS LIMITED OVERSEAS SERVICE DEPARTMENT Tokyo. without the written consent of ISUZU MOTORS LIMITED. I This manual is applicable for vehicles in all countries except USA and Canada. in whole or in part. Copyright reserved.. Japan First edition Jun. This manual may not be reproduced or copied.

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