Isuzu N-Series. Service manual — part 640

6E-8 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Installation

1. EGR Valve

• Install the gasket to the intake manifold.
• Install the EGR valve and tighten the nuts to the

specified torque.

Tighten:

• Nut to 24 N

⋅m (2.4 kg⋅m / 17 lb⋅ft)

2. EGR Pipe

• Install the gasket to the EGR valve.
• Install the EGR pipe and tighten the bolts to the

specified torque.

Tighten:

• Bolt to 19 N

⋅m (1.9 kg⋅m / 14 lb⋅ft)

3. EGR Cooler

• Install the gaskets to the EGR pipe and the exhaust

manifold.

• Install the EGR cooler.
• Tighten the nuts until they seat (do not final tight-

en).

4. EGR Cooler Bracket

• Install the bracket to the EGR cooler.
• Install the washer to the flywheel housing side.
• Tighten the bolts until they seat (do not final tight-

en).

Tighten the nuts and bolts to the specified torque in the
order shown in the illustration.

Tighten:

• Nuts to 24 N

⋅m (2.4 kg⋅m / 17 lb⋅ft)

• Bolts to 19 N

⋅m (1.9 kg⋅m / 14 lb⋅ft)

N6A3588E

N6A3589E

N6A3590E

EXHAUST GAS RECIRCULATION (EGR) SYSTEM 6E-9

N6A3591E

ENGINE EXHAUST 6F-1

ENGINE 4J SERIES

SECTION 6F

ENGINE EXHAUST

Caution:
Exhaust system components must have enough clearance from the underbody to prevent overheating of the floor
pan and possible damage to the passenger compartment, insulation and trim materials.

Contents

GENERAL DESCRIPTION . . . . . . . . ... 6F-2
THREE WAY CATALYTIC CONVERTER . . . 6F-3

On-Vehicle Service. . . . . . . . . . . 6F-3

FRONT EXHAUST PIPE. . . . . . . . . ... 6F-4

Component . . . . . . . . . . . . . . 6F-4
Removal . . . . . . . . . . . . . . . 6F-4
Installation . . . . . . . . . . . . . . . 6F-4

EXHAUST BRAKE UNIT. . . . . . . . . ... 6F-6

Inspection . . . . . . . . . . . . . . .. 6F-6

6F-2 ENGINE EXHAUST

GENERAL DESCRIPTION

Model

′91/542B (Euro 2)

General Export

When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on
the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation
and trim materials.
Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes
to seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may be an in-
dication of a problem in one of these areas. Any faulty areas should be corrected immediately.

N6A3592E

N6A3593E