ISUZU KB P190 2007 Workshop Repair Manual

6F – 8 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail.








RTW 46ELF001101



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EXHAUST SYSTEM 6F – 9
EGR SYSTEM DIAGRAM 4JA1T (L)




RTW 46AMF000301

EGR System Operation
Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up.
• Inspection point (Engine RPM)

RPM Idling 900 ∼ 960 2000 3250
Engine Front Side VSV-1
ON ON ON OFF
Engine Rear Side VSV-2 ON OFF ON OFF

ON means VSV should receive signal to move EGR valve.
OFF means VSV shouldn’t receive signal to move EGR valve.



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6F – 10 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail.


RTW 46EMF000701

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EXHAUST SYSTEM 6F – 11
INSPECTION
4JA1T(L)



Vacuum switch valve (VSV)
Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance Ω at 20°C
37 ~ 44

If the resistance is not within specification, replace it.



EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.

Negative Pressure








4JA1TC/4JH1TC




RTW 46ESH000301


EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance Ω at 20°C
14

If the resistance is not within specification, replace it.

EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.

Negative Pressure 4JH1TC
Less than 250 mmHg Not operation
More than 300 mmHg Operation

Negative Pressure 4JA1TC
Less than 100 mmHg Not operation
More than 170 mmHg Operation
Less then 180 mmHg Not operation
More than 240 mmHg
Operation

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6F – 12 EXHAUST SYSTEM
EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL)
REMOVAL AND INSTALLATION




RTW 46EMF000201

Removal Steps
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt


7. EGR Pipe Assembly
8. Gasket
9. Bolt
10. EGR Cooler Assembly
11. Gasket
12. EGR Cooler Adapter


Removal
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
7. EGR Pipe Assembly
8. Gasket
9. Bolt
10. EGR Cooler Assembly
11.Gasket
12.EGR Cooler Adapter

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EXHAUST SYSTEM 6F – 13





RTW 46EMF000901

Installation steps
1. EGR Cooler Adapter
2. Gasket
3. EGR Cooler Assembly
4. Gasket
5. Bolt
6. EGR Pipe Assembly
7. Bolt



8. Bolt
9. Gasket
10. EGR Valve Assembly
11. Bolt
12. EXH Manifold
13. Gasket
14. Bolt


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6F – 14 EXHAUST SYSTEM



























Installation
1. EGR Cooler Adapter
2. Gasket
3. EGR Cooler Assembly
4. Bolt
Tighten the bolts to the specified torque.
EGR adapter bolt torque N⋅m(kg ⋅m/lb ft)
27(2.8/20)
5. Gasket
6. EGR Pipe Assembly
7. Bolt
Tighten bolts temporarily.
8. Bolt
Tighten bolts temporarily.
9. Gasket
10. Bolt
Tighten bolts temporarily.
11.Gasket
12.Bolt
Tighten bolts temporarily.
Finally tighten all bolts to the specified torque.
Confirm that there is no misalignment on the sealing surface.
Bolt torque (Cooler-pipe) N ⋅m(kg ⋅m/lb ft)
27(2.8/20)
Bolt torque (Cooler-bracket) N ⋅m (kg ⋅m/lb ft)
24(2.4/17)
Bolt torque (Adapter-EGR valve) N ⋅m (kg ⋅m/lb ft)
27(2.8/20)
Bolt torque (Pipe-manifold) N ⋅m (kg ⋅m/lb ft)
27(2.8/20)





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EXHAUST SYSTEM 6F – 15
TURBOCHARGER
MAIN DATA AND SPECIFICATIONS
Engine 4JA1T(L) 4JA1TC 4JH1TC
Model IHI RHF4H IHI RHF4H IHI RHF5
Turbine type Mixed type
Compressor type Backword & rake type
Maximum permissible speed rpm 190,000 190,000 180,000
IHI : Ishikawajima Harima Heavy Industries., Ltd.



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6F – 16 EXHAUST SYSTEM
GENERAL DESCRIPTION


036LV002

The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings.
These parts are supported by the bearing housing.
The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing
air exhaust port.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger is indicated.

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EXHAUST SYSTEM 6F – 17

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.






















Turbocharger pressure check
1. Remove the hose between the waste gate and the
compressor outlet pipe.
2. Connect the pressure gauge. To compressor outlet pipe.
3. Start the engine and gradually increase the engine speed (the vehicle must be stationary with no load
applied to the engine).
4. Check to see that turbocharger pressure rises to approximately 141.3 Kpa (1060 mmHg).
Pressure Gauge : 5-8840-0075-0
150RY00030

Waste gate operation check
1. Remove the hose between the waste gate and the compressor outlet pipe.
2. Connect the pressure gauge. To waste gate actuator.
3. Check to see that the rod begins to move when a pressure of approximately 118 Kpa (885 mmHg) is
applied to the waste gate.
Note:
Do not apply a pressure greater than 150Kpa (1125
mmHg) to the waste gate during this check.
150RY00031
Unit Inspection (Remove Turbo. from engine)
Check to see the pressure required to move the control
rod 2 mm is within the limits shown below.
Kpa/mmHg
4JH1TC 134.8/1011
4JA1TC 147.7/1108



150RY00032
Contact the “ISUZU MOTORS LIMITED” Dealer service
department or “IHI SERVICE FACILITY” for major repairs
and maintenance.
Important wheel shaft end play and bearing clearance
standards and limits are included below for your reference.

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