How to Remove & Install Exhaust Manifold for ISUZU 4JJ1 Engine

This instruction show you guide on how to remove and install exhaust manifold for ISUZU Euro 4 N series truck 4JJ1 engine.If you want more about ISUZU truck cases,please refer to::ISUZU Trouble Repair.

 

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How to Remove & Install Inlet Manifold for ISUZU 4JJ1 Engine Truck

 

Procedures:

Removal

1.Drain the engine coolant.

2.Remove the front exhaust pipe and exhaust brake.

3.Remove the generator.

4.Remove the turbocharger assembly.

5.Remove the EGR cooler.

6.Remove the exhaust manifold heat protector.

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7.Remove the exhaust manifold and gasket.

NOTE: Do not reuse the gasket.

Inspection

Inspection of the exhaust manifold Inspect the flatness of the installation surface of the manifold and cylinder head.

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NOTE: Replace if the flatness is beyond the repair limit.

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Visually check the exhaust manifold for cracks.

 

Installation

1.Install the exhaust manifold.

a.Assemble the projection section(1) of the gasket to the engine rear side.

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b.Install the exhaust manifold. washer and bolt are installed, and tightened temporarily as shown in figure.

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Legend

1.Stud bolt

2.Washer

3.Nut c. Tighten at the specified torque in the order shown in the diagram.

Tightening torque:52 N-m(5.3kg-m/38 Ibft)

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2.Install the exhaust manifold heat protector.

Tightening torque:25 N-m(2.5kg-m/18 Ibft)

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3.Install the EGR cooler.

4.Install the turbocharger assembly.

5.Install the front exhaust pipe and exhaust brake.

6.Install the generator.

7.Refill the engine coolant.

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