Isuzu c223 turbo Instruction manual

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
1GENERAL
INFORMATION
2ENGINE ASSEMBLY
3LUBRICATING
SYSTEM
*4 COOLING SYSTEM
5FUEL SYSTEM s
-.\$
si ir
6INTAKE AND
EXHAUST SYSTEM
*7 AUXILIARIES
*8 SPECIAL TOOL LIST
ICONVERSION TABLE
'Not 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
$.Q - ./,9
, :.1,6 - 7.0
7.8 - 11.7
7.3 - 10.9
10.6 - 16.0
10.2 - 15.2
f5.4 - 23.0
,!1-O_1;31;6
25.6 :42.2
36.6 - 55
0.5 - .:1.0
1.2 -'t'r.g-
':1,' :" l
2.8 - 4.7
2.8 - 4.6
6.2 - 9.3
5.8 ; 8.6
9.5'-. 1'4.2
9.0 ,- 13.4
13.8 - 20.8
13.2 : 19.8
19.9 - 29.9 ;i*
! t'l
27.5 - 41.5*- .
37.0-55.5j.J
:i
43.9 - 72.5 'z
1.7 - 3.1
r.*. .r'3,.8 - 6.4
.J
3.7 - 6.1
7.7 - 11.6
,fl.3 : Jo.e
- -: !+tr-<'* t
11 .6 - 17.4
10.9 - 16.3
r 6.3 - 24.5
15.6 - 23.4
,i" ""- J,3.4 - 35.2
E _j+-"F'.$,t32.3 - 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

1 -1O GENERAL INFORMATION
Timing belt train
TURBOCHARGER
Disconnect boost hose at injection pump side.
lnstall boost pressure gauge.
Take measurement with specified engine speed at no load.
1.
2.
3.
Check boost hoses for loose connection or leakage.
Check turbocharger mounting or connection for leakage or
loose.

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

1 -12 GENERAL INFORMATION
RECOM MENDED LUBRICANTS
h
: : lil
, ! il
j 1i1.
ii, . :.1
il
'Jl
.11
;ir
il'
t- i: ..*
irt
:i;'
LUBRICANT
Engine
Engine cooling system
MAKE AND BRAND
CD grade
* 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 DIESEL SIGMA
MOBIL DELVAC 12OO SERIES
MOBIL DELVAC 13OO SERIES
MOBIL DELVAC SUPER
MOBIL DELVAC SHC
SHELL RIMULA CT OIL
SHELL RIMULA X OIL
SHELL MYRINA OIL
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
CALTEX AF COOLANT
CASTROL ANTI-FREEZE
CHEVRON ATLAS PERMA-GUARD
ANTI-FREEZE AND COOLANT
ENI AGIP F.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
* Mark ... lsuzu genuine lubricants
Diesel engine oil
CD grade
Permanent type anti-
freeze solution

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

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

2-2 ENGINE ASSEMBLY
INSPECTION AND REPAIR
Piston pin
Visually inspect for damage, wear or other abnormal conditions.
Outside diameter
Measure
ference. at several points
Fitting interference between piston pin and piston pin hole.
Piston
Clearance between piston ring and ring grove
Standard Limit
1st compression ring o.120 - o.155 o.185
2nd compression ring 0.050 - 0.085 o.1 15
Oilring 0.030 - 0.070 0.100
Piston ring
Remove deposit of carbon from piston rings and check for wear
and damage.
lnsert the piston ring into bore and push it in, at a right angle to
the wall, deep enough to reach the point where the cylinder bore
diameter is smallest then measure the ring gap.
Piston ring gap:
tr
@(mm)
Standard Limit
29.0 28.97
(mm)
114(4.2188in.)
oo
C
3
.2
1st, 2nd compression - o.4

ENGINE ASSEMBLY 2-3
,in;c5s5;l:mq
gJry-%:g
16, Cylinder head assembly
Tighten the cylinder head bolts in sequence as shown in the
figure.
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 illustatiod.

TUBRICATING SYSTEM 3-1
sEcTloN 3
LUBRICATING SYSTEM
INDEX
CONTENTS PAGE
General description ... 3-1
GENERAL DESCRIPTION
fl =:: Oil pres3ure switch
Oil filter and cooler assembly
I Fitter canridqe
llr-r r-
Valve
opening
pressure
3.5k9/cm2
Oil pan

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