4JH1 ISUZU KB P190 2007 Workshop Repair Manual

Engine Control System (4JH1) 6E-299
Special Tools and Equipment
Special Tools and Equipment
Illustration Tool Number/
Description
Illustration Tool Number/
Description
5-8840-2835-0 /
J-35616-A
Connector Test Adapter Kit
(W ith Test Lamp)
5-8840-0607-0 /
J-34142-B
Test Lamp
5-8840-0285-0 /
J-39200
Digital Multimeter
5-8840-0279-0 /
J-23738-A
Vacuum Pump
Tech2 Kit

Breaker Box

Adapter Harness


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SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 6F - 2
General Description .......................................................................................................... 6 F - 3
Removal and Installation .................................................................................................. 6F - 4
Inspection and Repair ....................................................................................................... 6F - 6
General Description .......................................................................................................... 6 F -7
EGR System Diagram........................................................................................................ 6F 9
Inspection ..................................................................................................................... ..... 6F-11
EGR Cooler (4JA1TC/4JH1TC Euro-III model)................................................................. 6F-12
Turbocharger ................................................................................................................... .. 6F -15
Main Data and Specifications....................................................................................... 6F -15
General Description .......................................................................................................... 6 F -16
Inspection and Repair ....................................................................................................... 6F -17
Special Tools .................................................................................................................. ... 6F -19
IHI Service Network ........................................................................................................... 6F -20
EXH
AU ST SY STEM 6F – 1

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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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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 – 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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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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6H – 4 ACCELERATOR CONTROL

4JA1TC, 4JH1TC/RHD






RTW 46HLF000201

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ACCELERATOR CONTROL 6H – 5

4JA1TC, 4JH1TC/LHD




PTW 46BMF000101


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