ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Exhaust Manifold

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REMOVAL & INSTALLATION



1.8L, 2.0L and 2.3L Engines

See Figure 1



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Fig. Fig. 1: Exhaust manifold for 1.8L, 2.0L and 2.3L engines. Always apply anti-seize compound to nuts, studs and oxygen sensor threads during assembly

  1. Disconnect the negative battery cable and remove the air cleaner assembly.
  2.  
  3. Remove the EGR pipe clamp bolt at the rear of the cylinder head.
  4.  
  5. Raise and safely support the vehicle. Remove the EGR pipe from the intake and exhaust manifolds.
  6.  
  7. Disconnect the exhaust pipe from the exhaust manifold. Disconnect the electrical connector from the oxygen sensor.
  8.  
  9. Remove the manifold shield and heat stove.
  10.  
  11. Remove the manifold retaining nuts and remove the manifold from the engine.
  12.  

To install:
  1. Using a new gasket, install the exhaust manifold and torque the nuts to 14-18 ft. lbs. (20-25 Nm).
  2.  
  3. Install the heat stove and shield.
  4.  
  5. Connect the exhaust pipe to the exhaust manifold. Connect the electrical connector to the oxygen sensor.
  6.  
  7. Install the EGR pipe to the intake and exhaust manifolds and lower the vehicle.
  8.  
  9. Install the EGR pipe clamp bolt to the rear of the cylinder head.
  10.  
  11. Install the air cleaner. Connect the negative battery cable.
  12.  

2.2L Gasoline Engine

CAUTION
Allow the engine to cool to ambient temperature before removing the exhaust manifold.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake air duct.
  4.  
  5. Label and disconnect the hoses and wiring.
  6.  
  7. Remove the oil dipstick tube.
  8.  
  9. Remove the power steering brace mounting bolts. Remove the air conditioning compressor braces.
  10.  
  11. Remove the manifold heat shield.
  12.  
  13. Disconnect the front exhaust pipe from the exhaust manifold.
  14.  
  15. Uncouple the oxygen sensor electrical connector.
  16.  
  17. Loosen the exhaust manifold nuts in a crisscross pattern.
  18.  
  19. Remove the exhaust manifold from the cylinder head. If it sticks, tap it with a soft-faced mallet.
  20.  

To install:

Install the new exhaust manifold gasket with the stamped mark facing outward.

  1. Inspect the exhaust manifold mating surfaces for warpage or other damage. Replace if necessary. The warpage limit is 0.016 in. (0.4mm).
  2.  
  3. Using a new gasket, install the exhaust manifold. Tighten the manifold nuts in a crisscross pattern starting in the center and working outward to 115 inch lbs. (14 Nm).
  4.  
  5. Install the tube and the dipstick if they were removed.
  6.  
  7. Connect the exhaust pipe to the exhaust manifold. Tighten the nuts to 49 ft. lbs. (67 Nm).
  8.  
  9. If the oxygen sensor was removed, coat its threads with a small amount of anti-seize compound. Don't get any anti-seize on the sensor's tip. Install the sensor and tighten its fitting to 31 ft. lbs. (42 Nm).
  10.  
  11. Connect the electrical connector to the oxygen sensor.
  12.  
  13. Install the manifold heat shield.
  14.  
  15. Install the power steering and air conditioning braces.
  16.  
  17. Connect all wiring and hoses.
  18.  
  19. Install the intake air duct.
  20.  
  21. Connect the negative battery cable.
  22.  

2.6L Engine

See Figure 2



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Fig. Fig. 2: Exhaust manifold for a 2.6L engine. Always apply anti-seize compound to nuts, studs and oxygen sensor threads during assembly


CAUTION
Allow the engine to cool to ambient temperature before removing the exhaust manifold.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake air duct.
  4.  
  5. Label and disconnect the hoses from the air pump.
  6.  
  7. Release the air pump drive belt tension.
  8.  
  9. Remove the air pump mounting bolts. Slip the drive belt off the pulley and remove the air pump.
  10.  
  11. Remove the manifold heat shield.
  12.  
  13. Remove the EGR pipe clamp bolt from the rear of the cylinder head.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Disconnect the EGR pipe from the exhaust manifold.
  18.  

The dipstick and tube may be removed for extra access to the oxygen sensor and EGR pipe.

  1. Disconnect the front exhaust pipe from the exhaust manifold.
  2.  
  3. Uncouple the oxygen sensor electrical connector.
  4.  
  5. Loosen the exhaust manifold nuts in a crisscross pattern.
  6.  
  7. Remove the exhaust manifold from the cylinder head. If it sticks, tap it with a soft-faced mallet.
  8.  

To install:

Install the new exhaust manifold gasket with the stamped mark facing outward.

  1. Inspect the exhaust manifold mating surfaces for warpage or other damage. Replace if necessary. The warpage limit is 0.016 in. (0.4mm).
  2.  
  3. Using a new gasket, install the exhaust manifold. Tighten the manifold nuts in a crisscross pattern starting in the center and working outward to 33 ft. lbs. (44 Nm).
  4.  
  5. Install the tube and the dipstick if they were removed.
  6.  
  7. Connect the exhaust pipe to the exhaust manifold. Tighten the nuts to 49 ft. lbs. (67 Nm).
  8.  
  9. If the oxygen sensor was removed, coat its threads with small amount anti-seize compound. Don't get any anti-seize on the sensor's tip. Install the sensor and tighten its fitting to 31 ft. lbs. (42 Nm).
  10.  
  11. Connect the electrical connector to the oxygen sensor.
  12.  
  13. Install the EGR pipe to the intake and exhaust manifolds and tighten the bolts to 17 ft. lbs. (24 Nm).
  14.  
  15. Lower the vehicle.
  16.  
  17. Install the manifold heat shield.
  18.  
  19. Install the EGR pipe clamp bolt to the rear of the cylinder head.
  20.  
  21. Install the air pump and drive belt.
  22.  
  23. Connect the hoses to the air pump.
  24.  
  25. Install the intake air duct.
  26.  
  27. Connect the negative battery cable.
  28.  

2.8L Engine

See Figures 3, 4 and 5



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Fig. Fig. 3: Exhaust manifold-2.8L engine



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Fig. Fig. 4: Removing the exhaust manifold bolts-2.8L engine



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Fig. Fig. 5: Lifting the exhaust manifold from the cylinder head-2.8L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the exhaust pipe from the manifold.
  6.  
  7. Lower the vehicle and remove the rear manifold bolts.
  8.  
  9. On the right side, remove the diverter valve, the heat shield, the AIR pump bracket and alternator bracket.
  10.  
  11. On the left side, remove the heat stove tube and the power steering bracket.
  12.  
  13. Remove the exhaust manifold-to-cylinder head bolts and the manifold.
  14.  
  15. Clean the gasket mounting surfaces.
  16.  

To install:
  1. Using a new gasket, install the exhaust manifold-to-cylinder head bolts and torque the bolts to 25 ft. lbs. (34 Nm).
  2.  
  3. On the left side, install the power steering bracket and heat stove tube.
  4.  
  5. On the right side, install the AIR pump bracket, the alternator bracket, the diverter valve and the heat shield.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Install the exhaust pipe-to-manifold bolts.
  10.  
  11. Lower the vehicle and connect the negative battery cable.
  12.  

3.1L Engine

See Figure 6



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Fig. Fig. 6: Exhaust manifold and related components-3.1L engine

LEFT EXHAUST MANIFOLD
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the front wheels.
  6.  
  7. Remove the dust cover.
  8.  
  9. Disconnect the exhaust pipe from the exhaust manifold.
  10.  
  11. Remove the power steering pump bracket.
  12.  
  13. Remove the exhaust manifold mounting bolts.
  14.  
  15. Remove the exhaust manifold.
  16.  

To install:
  1. Install the exhaust manifold. Torque the mounting bolts to 25 ft. lbs. (34 Nm).
  2.  
  3. Install the power steering pump bracket.
  4.  
  5. Connect the exhaust pipe to the exhaust manifold.
  6.  
  7. Install the dust cover and the front wheels.
  8.  
  9. Lower the vehicle to the floor.
  10.  
  11. Connect the negative battery cable, start the engine and check for leaks.
  12.  

RIGHT EXHAUST MANIFOLD
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the front wheels.
  6.  
  7. Remove the dust cover.
  8.  
  9. Disconnect the exhaust pipe from the exhaust manifold.
  10.  
  11. Remove the generator support bracket.
  12.  
  13. Using a 6 point socket, remove the exhaust manifold mounting bolts.
  14.  
  15. Remove the exhaust manifold.
  16.  

To install:
  1. Install the exhaust manifold. Torque the mounting bolts to 25 ft. lbs. (34 Nm).
  2.  
  3. Install the generator support bracket.
  4.  
  5. Connect the exhaust pipe to the exhaust manifold.
  6.  
  7. Install the dust cover and the front wheels.
  8.  
  9. Lower the vehicle to the floor.
  10.  
  11. Connect the negative battery cable, start the engine and check for leaks.
  12.  

3.2L Engine

See Figures 7 and 8



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Fig. Fig. 7: Left side exhaust manifold-3.2L engine



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Fig. Fig. 8: Right side exhaust manifold-3.2L engine

LEFT EXHAUST MANIFOLD

Allow the engine to cool completely before removing the exhaust manifolds.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air duct.
  4.  
  5. Remove the EGR pipe mounting bolts from the exhaust manifold.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. If necessary to gain extra working room, remove the transfer case skid plate.
  10.  
  11. Label and disconnect the oxygen sensor connectors.
  12.  
  13. Remove the two stud nuts and two bolts and nuts and separate the front exhaust pipes from the exhaust manifold. Be careful not to damage the oxygen sensors when working around the exhaust pipes.
  14.  
  15. Lower the vehicle.
  16.  
  17. Remove the engine hanger and the heat shield.
  18.  
  19. Remove the seven nuts and then remove the exhaust manifold from the cylinder head.
  20.  

To install:

Use new self-locking nuts and new gaskets when installing the exhaust manifolds.

  1. Install the exhaust manifold and gasket to the cylinder head using new nuts. Tighten the new nuts to 42 ft. lbs. (57 Nm) in a crisscross sequence.
  2.  
  3. Install the heat shield and the engine hanger.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the front exhaust pipes and reconnect the exhaust system. Tighten the exhaust fasteners to the following specifications:
    1. Stud nuts: 49 ft. lbs. (67 Nm)
    2.  
    3. Flange nuts and bolts: 32-37 ft. lbs. (43-50 Nm)
    4.  

  8.  
  9. Reconnect the oxygen sensor connectors.
  10.  
  11. Install the skid plate and tighten the bolts to 27 ft. lbs. (37 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Install the EGR pipe to the exhaust manifold. Tighten the mounting bolts to 21 ft. lbs. (28 Nm).
  16.  
  17. Install the air duct and connect the negative battery cable. Verify that all wires and vacuum lines have been reconnected.
  18.  
  19. Start the engine and check for exhaust leaks.
  20.  

RIGHT EXHAUST MANIFOLD

Allow the engine to cool completely before removing the exhaust manifolds.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. If necessary to gain extra working room, remove the transfer case skid plate.
  6.  
  7. Label and disconnect the oxygen sensor connectors.
  8.  
  9. Remove the two stud nuts and two bolts and nuts and separate the front exhaust pipes from the exhaust manifold. Be careful not to damage the oxygen sensors when working around the exhaust pipes.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the engine hanger.
  14.  
  15. Remove the five heat shield mounting bolts and then remove the heat shield.
  16.  
  17. Remove the seven nuts and then remove the exhaust manifold from the cylinder head.
  18.  

To install:

Use new self-locking nuts and new gaskets when installing the exhaust manifolds.

  1. Install the exhaust manifold and gasket to the cylinder head using new nuts. Tighten the new nuts to 42 ft. lbs. (57 Nm) in a crisscross sequence.
  2.  
  3. Install the heat shield and the engine hanger.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the front exhaust pipes and reconnect the exhaust system. Tighten the exhaust fasteners to the following specifications:
    1. Stud nuts: 49 ft. lbs. (67 Nm)
    2.  
    3. Flange nuts and bolts: 32-37 ft. lbs. (43-50 Nm)
    4.  

  8.  
  9. Reconnect the oxygen sensor connectors.
  10.  
  11. Install the skid plate and tighten the bolts to 27 ft. lbs. (37 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Verify that all wires and vacuum lines have been reconnected.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Start the engine and check for exhaust leaks.
  20.  

 
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