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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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.

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.

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

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.

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

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)

2.Install the exhaust manifold heat protector.

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

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.