This instruction show you guide on how to remove and install turbocharger assembly for JCB HP 2010 with ISUZU INT-Tier4 engine.
Removal Guide:
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.
2 Coolant Drain
Drain the coolant from the radiator.
Caution: After the coolant is discharged, make sure to tighten the drain plug.
3 Turbocharger 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 assembly.is connect 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.
Remove the exhaust manifold stay from the cylinder block and the turbocharger assembly.
Disconnect the harness connector from the turbocharger assembly.
Remove the turbocharger assembly from the exhaust manifold.
Installation Guide:
Temporarily tighten the turbocharger assembly to the exhaust manifold.
Temporarily tighten the exhaust manifold stay to the cylinder block and the turbocharger assembly.
Securely tighten the turbocharger assembly to the exhaust manifold.
tightening torque： 52 N・m { 5.3 kgf・m / 38 lb・ft }
Securely tighten the exhaust manifold stay to the cylinder block and the turbocharger assembly.
tightening torque： 52 N・m { 5.3 kgf・m / 38 lb・ft } Nut
tightening torque： 50 N・m { 5.1 kgf・m / 37 lb・ft } Bolt
Note: Tightening order
Connect the water feed pipe to the turbocharger assembly.
Caution: Use new gaskets.
tightening torque： 35 N・m { 3.5 kgf・m / 25 lb・ft } Eyebolt
tightening torque： 14 N・m { 1.4 kgf・m / 119 lb・in } Clip
Connect the water return pipe to the turbocharger assembly.
tightening torque： 35 N・m { 3.5 kgf・m / 25 lb・ft } Eyebolt
Connect the oil return pipe to the turbocharger assembly.
Caution: Use new gaskets.
tightening torque： 9 N・m { 0.9 kgf・m / 78 lb・in }
Replenish the turbocharger assembly with the engine oil.
Connect the oil feed pipe to the turbocharger assembly.
Caution: Use new gaskets.
tightening torque： 29 N・m { 3.0 kgf・m / 21 lb・ft } Eyebolt
tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft } Clip
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.
Connect the harness connector to the turbocharger assembly.
Coolant Filling
Loosen the valve using a wrench.
Replenish the coolant with the radiator.
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： 28 N・m { 2.8 kgf・m / 20 lb・ft }
Replenish the coolant with the radiator.
Battery Ground Cable Connect
Connect the battery ground cable to the battery.
More repair cases for ISUZU engine,please refer to:ISUZU Engine Trouble Repair
More repair tool for ISUZU engine,please refer to: JCB Electronic Service tool