Isuzu Cars and Trucks 1981-1991

Exhaust Manifold

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REMOVAL AND INSTALLATION
G180Z, G200Z and 4ZD1 Engines
  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.  



Click image to see an enlarged view

Fig. Exhaust manifold assembly, including oxygen sensor G180Z, G200Z and 4ZD1 engines

To install:

  1. Using a new gasket, install the exhaust manifold and torque the nuts to 14 and 1918 ft. lbs. (20 and 1925 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.  

4XC1U and 4XE1 SOHC/DOHC Engine
  1. Disconnect the negative () battery cable.
  2.  
  3. Disconnect the oxygen sensor connector and remove the exhaust pipe from the exhaust manifold.
  4.  
  5. Remove the heat protector and EGR pipe with clip.
  6.  
  7. Remove the manifold retaining bolts and manifold.
  8.  



Click image to see an enlarged view

Fig. Exhaust manifold 4XC1-U engine

To install:

  1. Make sure the sealing surfaces are clean.
  2.  
  3. Install the manifold with a new gasket and torque the bolts to 30 ft. lbs. (39 Nm).
  4.  
  5. Install the EGR pipe with the clip. Torque the bolt to 32 ft. lbs. (44 Nm).
  6.  
  7. Install the heat protector and connect the oxygen sensor.
  8.  
  9. Reconnect the exhaust pipe to the manifold.
  10.  
  11. Start the engine and check for leaks.
  12.  

4XC1-T and 4ZC1-T (Turbo) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the lower and upper heat protectors.
  4.  
  5. Remove the wastegate manifold.
  6.  
  7. Remove the turbocharger assembly and manifold heat protector.
  8.  



Click image to see an enlarged view

Fig. Exhaust manifold and turbocharger assembly 4XC1-T engine



Click image to see an enlarged view

Fig. Exhaust manifold and turbocharger assembly 4ZC1-T engine

To install:

  1. Clean all gasket mating surfaces with a scraper.
  2.  
  3. Using new gaskets, install the exhaust manifold and torque the bolts to 15 ft. lbs. (21 Nm).
  4.  
  5. Install the turbocharger assembly and manifold heat protector.
  6.  
  7. Install the wastegate manifold.
  8.  
  9. Install the lower and upper heat protectors.
  10.  
  11. Connect the negative (-) battery cable, start the engine and check for leaks.
  12.  

4ZE1 Engine
  1. Disconnect the negative battery cable and remove the air duct.
  2.  
  3. Remove the hoses from the air pump.
  4.  
  5. Remove the air pump bolts, remove the drive belt and the air pump.
  6.  
  7. Remove the EGR pipe clamp bolt at the rear of the cylinder head.
  8.  
  9. Raise and safely support the vehicle. Remove the EGR pipe from the intake and exhaust manifolds. If necessary, remove the dipstick and tube.
  10.  
  11. Disconnect the exhaust pipe from the exhaust manifold. Disconnect the electrical connector from the oxygen sensor.
  12.  
  13. Remove the manifold shield.
  14.  
  15. Remove the manifold-to-cylinder head nuts and the manifold from the engine.
  16.  

To install:

  1. Using a new gasket, install the exhaust manifold and torque the nuts to 16 ft. lbs. (22 Nm).
  2.  
  3. Install the heat shield. If the dipstick was removed, install the tube and the dipstick.
  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 duct. Connect the negative battery cable.
  12.  

V6 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.  



Click image to see an enlarged view

Fig. Exhaust manifold assembly V6 engine

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.  

 
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