JCB ISUZU 6HK1 Engine Turbocharger Assembly Removal & Installation Guide

This illustration show you guide on how to remove and install turbocharger assembly fro JCB ISUZU 6HK1 INT-Tier4 engine.

 

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Procedures:

Removal:

1 Battery Ground Cable Disconnect

Disconnect the battery ground cable from the battery.

Caution: Do not disconnect the battery cable for 1 minute after turning OFF the ignition switch.

 

2Coolant Drain

Drain the coolant from the radiator.

Caution: After the coolant is discharged, make sure to tighten the drain plug.

 

3Turbocharger Assembly Removal

Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly.

Remove the air intake hose from the turbocharger assembly and the intercooler.

Remove the exhaust pipe from the turbocharger.

Disconnect the oil feed pipe from the turbocharger assembly.

Note: Remove the clip.

Disconnect the oil return pipe from the turbocharger assembly.

Disconnect the water return pipe from the turbocharger assembly.

Disconnect the water feed pipe from the turbocharger assembly.

Note: Remove the clip.

Disconnect the harness connector from the turbocharger assembly.

Remove the turbocharger assembly from the exhaust manifold.

JCB-ISUZU-6HK1-Engine-Turbocharger-Assembly-Removal-Installation-Guide-1

 

Installation:

1Turbocharger Assembly Installation

Replenish the turbocharger assembly with the engine oil.

Align the gasket to the turbocharger assembly.

Install the turbocharger assembly to the exhaust manifold.

tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

Connect the water feed pipe to the turbocharger assembly.

tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }

Caution: Use a new gasket.

Connect the water return pipe to the turbocharger assembly.

tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }

Caution: Use a new gasket.

Connect the oil return pipe to the turbocharger assembly.

tightening torque: 24 N・m { 2.4 kgf・m / 17 lb・ft }

Caution: Use a new gasket.

Connect the oil feed pipe to the turbocharger assembly.

tightening torque: 34 N・m { 3.5 kgf・m / 25 lb・ft }

tightening torque: 24 N・m { 2.4 kgf・m / 17 lb・ft } Clip

Caution: Use a new gasket.

JCB-ISUZU-6HK1-Engine-Turbocharger-Assembly-Removal-Installation-Guide-3

Install the exhaust pipe to the turbocharger assembly.

Install the air intake hose to the turbocharger assembly and the intercooler.

Install the air cleaner duct to the air cleaner assembly and the turbocharger assembly.

 

2Coolant Filling

Loosen the valve using a wrench.

Replenish the radiator with coolant.

Caution: Be careful not to let coolant overflow splash on the exhaust system parts.

Caution: Coolant overflow should be wiped off.

Tighten the valve using a wrench.

Caution: Use new gaskets.

tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft }

Replenish the radiator with coolant.

JCB-ISUZU-6HK1-Engine-Turbocharger-Assembly-Removal-Installation-Guide-1

 

3Battery Ground Cable Connect

Connect the battery ground cable to the battery.

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