Isuzu c223 turbo Workshop Manual Supplement

SUPPLEMENT

ISUZU

MOTORS

LIMITED

':

*

g

G

-CAMERON

&

SONS

PTY.

BOX

116

P.O.

oRANGE

2800

rrl

ISUZU

WORKSHOP

MANUAL

DIESEL ENGINE

C223 TURBO MODEL

SUPPLEMENT

FOREWORD

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-WE-

141l,.

This

manual includes

special notes,

important

points,

service data,

precautions,

etc.

that are needed

for

the

maintenance,

adjustments,

service,

removal

and

installation

of components of the models titled.

All

information,

illustrations

and

specificatioins

con-

tained in this manual

are

based on

the latest

product

information

available

at the time of

publication.

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.

This

manual applies

models.

1984

year

and later

SECTION

INDEX

SECTION

NAME

1

GENERAL

INFORMATION

2

ENGINE ASSEMBLY

3

LUBRICATING
SYSTEM

*4

COOLING

SYSTEM

5

FUEL SYSTEM

s

-.\$

si

ir

6

INTAKE AND
EXHAUST SYSTEM

*7

AUXILIARIES

*8

SPECIAL

TOOL LIST

I

CONVERSION

TABLE

included

Refer to C223-WE-141.

GENERAL

INFORMATION

1_1

sEcTloN

1

GENERAL

INFORMATION

INDEX

CoNTENTS

PAGE

Generat

repairinstructions....

....1-

1

How to use this

manual

. . . .

1-

2

Maindataandspecification

.......1-

5

Torquespecifications

..'.'.

1- 7

Servicing

'.....1-

I

Recommended

lubricants

..

.

1-12

Engineoil viscositychart

...1-13

Adhesive for repair

GENERAL

REPAIR

INSTRUCTIONS

1. For

assurance

of safety,

park

the

vehicle on level

ground

and

brace the

front

or

rear wheels

when lifting

the

vehicle.

2. Raise

the

vehicle

with

a

jack

set against

the axle

or frame

and

perform

service

operation

after supporting

the

vehicle

on chassis stands.

3.

Before

performing

service

operation, disconnect

grounding

cable

from the

battery

to

reduce

the chance

of

cable

damage

and

burning due

to

short-circuiting.

4.

Use a cover on body, seats

and

floor to

protect

them against

damage

and

contamination.

5.

Brake

fluid and anti-freeze solution

must be

handled

with

reasonable care as

they

can cause

paint

damage'

6.

The

use of

proper

tools

and special tools

where specified,

is

important to efficient

and

reliable service

operation.

7. Use

genuine

lsuzu

parts.

8. 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.

9. 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.

1

-2

GENERAL

INFORMATION

10.

Clean the

parts

before

inspection or

reassembly. Also

clean oil

ports,

etc. using compressed

air

to make

certain

they

are free

from restrictions.

1 1. Lubricate rotating and sliding

faces

of the

parts

with oil or

grease

before

installation.

12. When

necessary,

use

a sealer

on

gaskets

to

prevent

leakage.

13.

Carefully observe

all specifications

for

bolt and

nut

torques.

14, When

service

operation is completed, make a

final check to be sure service

has

been done

properly.

15. For

assurance of

safety,

always

release

air

pressure

solely

from

the air

tanks before disconnecting

pipes,

hoses or

other

parts

from

any unit under air

pressure.

HOW TO

USE

THIS MANUAL

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.

Find

the

applicable

section by

refering

to the

index.

This

manual includes

"General

information" section

in which

service data,

maintenance

items and

specifications

with

torques are

included.

Each

section

includes

removal

and

installation, disassembly,

inspection and

repair

and

reassembly.

When

the

same service

operation applies to more than one un;ts

or equipments.

notice is inserted stating,

"Refer

to manual

for

other units

or equipments".

ln removal

and

installation

section. description

of self-explanatory

items such as

removal of individual

parts

from

unit to be

removed, is omitted

and

important operation

such as

adjustments,

torque specifications,

etc. are

dealt

with

mainly.

6.

The

service standard

is indicated in terms

of

"Standard"

and

"Limit".

The

"standard"

means the assembly

standard

and standard

range within which the

parts

are considered

serviceable.

"Limit"

indicates the limit

value

(Correction

or

replacement

is necessary

when

measurement

is beyond this

limit.)

7.

ln

this

manual, the components and

parts

are

printed

in

singular

form.

1.

,4'

2.

3.

4.

5.

GENERAL

INFORMATION

1-3

8.

Each

service operation

section begins

with

disassembled

view

of unit

or equipment which

is useful

to find

compo-

nents, service

procedure,

availability and content of

repair

kits,

etc.

MA'OR COMPONENT

Thi, illurtration b b.!.d on th. 6

r

6 and

4 r 4 modolr.

Tha ltaF of srvice otsralaon

d..iFat d as

No.

3 - 12

are eppliQble

to sll

modclr

€rcluding

6

x 4

2A

I I rt25

$@bu,

-"-}a.^

-----:l

--l_"

Rmfi5ly

tt

p.

al.

lnpd 3hafr b..ring

2. lnput thalt $afine

13.

Front

output 3h.lt baaring

4. Front

output ah.lt

3nrpring

5.

Front

outpt rhaft

6. Shitt

lork

.nd rld.

7.

Front

driva

lhifr

tork

.8.

F.@t

output rhaft,l6va

49.

Front

driv.

.hitt rod .nd coll.r

ll0.

Front

driy. ,hift

to.k l@k bolt

I l.

Front

drir.

rhilt

rod d.t.nt

blll,

rpring lnd

nai

^12.

Front

d.ivc.hift to.k ldk

wi..

^13.

lnput

rhaft

14. Shitt

iort, idl..hrft

.nd dcvc

15. ldl. th.tt.smbly

16. Hish.nd low.hittlork

^17.

lnput rh.tt rl.rv!

^18.

Hieh

md low shift

rod

.19.

High.nd

low thih fo.k lmk bolt

m.

High .d ld.hift

rod d.r6nt b.ll, ipri.0.nd cat

421.

High

ard

low thift

lork ldk

wit€

422,

nrar covar arsmbly

^23.

ldl..h.tl thim

24.

ldla th.ft @vd

25.

Front output lhalt dirt.ne

pi.6

26.

Front outpul rh.lt oil $d

^27.

Front

output lhatt

llanga.nd nut

28.

lnput shah

di.t.n6

pi.c.

29.

lnput rhatt oil sal

aA).

lnpd.h.lt

yok.

and

nut

^31.

lnpul

fialt

univ.rsl

ioint

8..athar

__l

"Note"

indicating

models applicable.

*

parts

contained in

repair kit.

Parts

to

be

removed

or installed as a

unit.

All

units or

parts

within frame are to be

considered

as

"major

component".

Each

unit

or

part

within frame

is to

be

considered

as

"minor

component".

The

number

represents sequence

of

service

operation.

Removal

of the

parts

without

number

(excluding

bolts,

nuts,

washers,

gaskets,

cotter

pins,

etc.) is unnecess-

ary

unless

when replacement is

needed.

Where

parts

replacement

requires

specific

note, instructions

are

given

in

"lnspection

and

repair"

*

indicates

repair kit

availability.

Name

of

parts

listed in

sequence

of

service operation.

A

indicates

important

operation.

Details

of service operation

are

described in the

paragraph

"lmportant

operations".

1-4

GENERAL INFORMATION

V

@

lmportant operrtions
l lnFlrh6ftb€rring

-

3.

Front

outpul

ftrft b.rring

lnstaller. 9.8522.0O4O.0

_r\

__r-t\_____r_.\

8.

F?ont

dtpul !h.lt tlolvr

17.

lnput

rheft

rloor.

The

shitt lork

groove

side taces downward.

I

rdr

-

oool

H'9h

6.d

low

rh't ro.

1r@nr

d

ooj

L

Front

dra !h,lt

rcd

L-

"i-l

9.

F.ontdrivcrhih

rod.rd coll.r

18. High.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€ carefullv nored.

To,que

ltg

ml

4

5 5

Fronl driv. ihilt

lork lock bolt

High

lrd

low

shiti

lork lock bll

Item

shown in the illustration

and

marked

with

"4"

Special

tools

are identified

with

tool

name

and/or

part

number.

The

drawing illustrates

how

the

tool is

used.

lmportant

note.

The

symbol

indicates the step

of ser-

vice to be

followed.

Refer to the

following

paragraph

for

meaning of each symbol.

Service

data

and

specif ications

are

listed

in table.

9. The

section following

illustration(s)

deals

with

important

service

steps marked with

"A"

This

section

also includes

"notes".

"use

of

special tools",

"service

data", etc.

10.

ln

this manual.

the

following

symbols are used to

indicate

the type

of

service

operations to

be

performed.

tr

E

E
E

H

E

tr

@

. Remove
.

lnstall

.

Disassemble

Reassemble

Align

the

marks

Correct

direction

lnspect

Take measurement

Adjustment

Clean

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

ffi

6

V

q

@

@[

tr

tr

11.

The

special tools with

part

number

preceded

by the

alphabet

"J"

are manufactured

by

Kent-Moore

Corporation.

These

tools are also

available at local outlet of

Kent-Moore Corporation

throughout the

world.

GENERAL INFORMATION 1

-5

MAIN DATA AND SPECIFICATIONS

Engine model

Items

c2237

Engine

type

Combustion chamber type

Cylinder liner type

Timing

gear

system

No.

of

piston

rings

No.

of cylinders

-

Bore

x

stroke

(mm)

Total

piston

displacement

(cc)

Compression

ratio

Engine

dimensions

:

lengthxwidthxheight

Engine weight

(dry)

Fuel

injection order

Fuel injection timing

(B.T.D.C.

static)

Type of fuel used

Fuelfilter

type

lnjection

pump

type

Governor type

lnjection nozzle type

Fuel

injection

pressure

Compression

pressure

ldle

speed

lntake

and

exhaust

valve

clearance

lntake valve 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

- voltage

Generator

Voltage

Starter

Voltage

(titers)

(liters)

capacity

output

v)

v-A)

V.KW)

(mm)

(kg)

(tg/cm')

(kg/cm'z)

(rpm)

(mm)

Water-cooled,

4-cycle

in-line,

overhead

valve

type

Swirl chamber

type

Combined

with

cylinder block

(Liner

less)

Gear

drive/Belt

drive

Compression

ring2,oil

ring

1

4-88x92

2238

21

:1

Approx.

741

x546 x7'l

6

A,pprox.22O

1-3-4-2

6o

(for

gear

drive)

1O"

(for

belt drive)

High-speed

dieselfuel

(SAE

No.

2)

Cartridge type

Bosch

distributor

VE

type

with

boost

compensator

Mechanicalvariable

speed

(half

all speed)

Throttle type

135

31

(at

2OO

rpm)

725

-775

(in

cold)

0.4

1 1"

(B.T.D.C.)

49'(A.B.D.C.)

51'

(B.B.D.C.)

9"

h.T.D.C.)

Pressurized circulation

Gear

tYPe

Paper

element

partial-flow

tYPe

With

oiling

jets

6.5

Water-cooled

Pressurized

circulation

9.O

lmpeller tyPe

Wax

pellet

type

(with

jiggle

valve)

Paper

element

tYPe

NS70

-

12

12-40

12

-

2.O

I€

ENEfiAT.'

I

NFO

RMATION

Engine

model

Items

c2237

Turbocharger

type

turbine

type

compressor

type

Maximumspeed", (rpm)

Maximumair

delivery

(kg/min.)

Maximum pressure

ratio

Wastgate

controlcariblation

(mmHg)

Boost

pressure

(mmHg)

TBO209

Radial,

inward-flow

Radial,

outward-flow

140.OOO

6.60

1.85

690

:t

20

28O

or more

at4,OO0

engine rpm

:,iGEff'EftAftel

mqmffim@fl

.€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.

1

ri

I, i:

-S.3

,

The

asterisk' indicates

that the

bolts

arb used

for female-thieadgd

part6'thbt

are

made of soft

materials

such as

casting,

:

etc.

, r\.{.

"",:,:ri

il

t'a_:

-il

(kg-m);

Bolt

identif ication

Bolt
diameter

x

pitch

(mm)

4T

"

(Low

carbon steel)

l,

7T

(High

carbon

steel)

9T

(Alloy

steel)

6 x

1.O

8 x

1.25

10

x

1.25

'1O

x 1.5

-

r't

'12

x

1.fr

'12 x

1.75

14

x

1.5

'14 x

2.O

16

x

1.5

116

x 2.0

\8'x 1.5

Q\,r"

\O

x--1.5

22\ 1.s

:

24.

io

0.4 - o.8

0.8

-

1.8.

2.1

-

3.5

2.O

-

3.A

$.Q

-

./,9

,

:.1,6

-

7.0

7.8

-

11.7

7.3

-

10.9

10.6

-

16.0

10.2

-

15.2

f5.4

-

23.0

,!1-O_1;31;6

25.6

:42.2

36.6

-

55

0.5

-

.:1.0

1.2

-'t'r.g-

':1,'

:"

l

2.8

-

4.7

2.8

-

4.6

6.2

-

9.3

5.8

;

8.6

9.5'-.

1'4.2

9.0

,-

13.4

13.8 - 20.8

13.2

:

19.8

19.9

-

29.9 ;i*

!

t'l

27.5

-

41.5*-

.

37.0-55.5j.J

:i

43.9

-

72.5

'z

1.7

-

3.1

r.*.

.r'3,.8

-

6.4

.J

3.7

-

6.1

7.7

-

11.6

,fl.3 : Jo.e

-

-:

!+tr-<'*

t

11

.6

-

17.4

10.9

-

16.3

r

6.3

-

24.5

15.6

-

23.4

,i"

""-

J,3.4

-

35.2

E

_j+-"F'.$,t

32.3

-

48.5

'

,'

43.3

-

64.9

.

56.5

-

84.7

;:il

-#

{t#

1

-8

GENERAL

INFORMATION

MAJOR

PARTS

FIXING

BOLTS

Cylinder

head

and

injection

pump

(kg-m)

----4

Y

ffi1-@

1.3-1.8(1F13)

1.8-2.411T171

2.2-3.2116-231

-"'t:

?C

__-tr.:---

':'.O----H,

16-18(116-130)

GENERAL INFORMATION

1

_9

'i€ffi3:434':):

-ffi-rio=a

ffi

CYLINDER

HEAD

INJECTION

TIMING

SERVICING

Tighten

the

cylinder head bolts

in

sequence as shown

in

the

f igure.

Torque

Tighten

the

cylinder

head

bolts

to the

specified angle

in

sequence above.

Angle

Apply

bisulfide molybdenum

grease

to thread

and contact sur-

face when

using used bolt.

(See

the

illustrationl.

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.

(mm)

0.5

@

t

st step

(snug

torque)

I

I

(t

6o

(for

gear

drive)

1Oo

(for

belt drive)

Standard reading