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Isuzu Cars and Trucks 1981-1991

Combination Manifold

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REMOVAL AND INSTALLATION
C223 and C223-T Diesel Engine

Although the intake and exhaust manifolds are individual parts, they must be remove at the same time so the 1-piece gasket may be replaced.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and air duct, if necessary.
  4.  
  5. Disconnect the accelerator cable from the throttle body.
  6.  
  7. Label and disconnect the necessary vacuum hoses and electrical connectors.
  8.  
  9. If not equipped with a turbocharger, disconnect the exhaust manifold from the exhaust pipe.
  10.  
  11. If equipped with a turbocharger, perform the following procedures:
  12.  
    1. Disconnect the intake and exhaust hoses from the turbocharger.
    2.  
    3. Disconnect the oil lines from the turbocharger.
    4.  
    5. Remove the turbocharger-to-exhaust manifold nuts, the turbocharger assembly-to-exhaust pipe nuts and the turbocharger assembly.
    6.  

  13. Remove the intake manifold-to-cylinder head bolts and the intake manifold.
  14.  
  15. Remove the exhaust manifold-to-cylinder head bolts, the exhaust manifold and discard the gasket.
  16.  
  17. Clean the gasket mounting surfaces.
  18.  



Click image to see an enlarged view

Fig. Combination manifold assembly C223 and C223-T engines

To install:

  1. Using a new gasket, install it onto the cylinder head with the center mark facing outward and upward.
  2.  
  3. Install the exhaust and intake manifolds onto the cylinder head and torque the nuts/bolts to 10 and 1917 ft. lbs. (14 and 1925 Nm) [non-turbocharged engine] or 13 and 1917 ft. lbs. (17 and 1925 Nm) [turbocharged engine].
  4.  
  5. If not equipped with a turbocharger, install the exhaust manifold to the exhaust pipe.
  6.  
  7. If equipped with a turbocharger, perform the following procedures:
  8.  
    1. Refill the turbocharger with clean engine oil.
    2.  
    3. Install the turbocharger-to-exhaust manifold nuts to 16 and 1923 ft. lbs. (24 and 1932 Nm) and the turbocharger assembly-to-exhaust pipe nuts to 16 and 1923 ft. lbs. (24 and 1932 Nm).
    4.  
    5. Connect the oil feed lines to the turbocharger.
    6.  


V6 Engine
  1. Relieve the fuel pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Label and disconnect the wires and hoses from the TBI unit and the intake manifold.
  2.  
  3. Disconnect and plug the fuel lines from the TBI unit.
  4.  
  5. Disconnect the accelerator cables from the TBI unit.
  6.  
  7. Disconnect the ignition wires from the spark plugs and the wires from the coil.
  8.  
  9. Remove the distributor cap with the wires.
  10.  
  11. Mark the location of the rotor to the distributor housing and the distributor housing to the intake manifold.
  12.  
  13. Remove the distributor hold-down clamp and the distributor.
  14.  
  15. Label and disconnect the EGR vacuum line and the emission hoses.
  16.  
  17. Remove the pipe brackets from the rocker arm covers.
  18.  
  19. Remove the rocker arm covers.
  20.  
  21. Remove the upper radiator hose and the heater hose.
  22.  
  23. Disconnect the electrical connectors from the coolant sensors.
  24.  
  25. Remove the intake manifold nuts/bolts, the manifold and gaskets.
  26.  
  27. Clean the gasket mounting surfaces.
  28.  



Click image to see an enlarged view

Fig. Intake manifold assembly V6 engine

To install:

  1. Using RTV sealant, apply an 3mm ( 1 / 8 in.) bead to the front and rear of the block; make sure no water or oil is present.
  2.  
  3. Using new gaskets, marked right and left side, apply a 6mm ( 1 / 4 in.) bead of sealant to hold them in place and install them onto the cylinder heads; the gaskets may have to be cut to be installed around the pushrods.
  4.  
  5. Install the intake manifold and torque the nuts/bolts, in sequence, to 23 ft. lbs. (31 Nm) and retorque using the same sequence.
  6.  


NOTE
Make sure the areas between the case ridges and the intake manifold are completely sealed.

  1. Install the heater hose and the radiator to the manifold.
  2.  
  3. Using new gaskets, install the rocker arm covers.
  4.  
  5. Connect the electrical connectors to the coolant sensors.
  6.  
  7. Install the pipe brackets.
  8.  
  9. Align the matchmarks and install the distributor and the distributor cap.
  10.  
  11. Connect the fuel lines and the accelerator cables to the TBI unit.
  12.  
  13. Connect all the wires and vacuum hoses.
  14.  
  15. Install the air cleaner. Connect the negative battery cable. Refill the cooling system.
  16.  

 
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