Isuzu engine 4j series. Manual — part 35

6A1 – 8 4JB1/4JB1T/4JB1TC/4JG2 - ENGINE

INLET MANIFOLD

REMOVAL

Preparation:

•

Disconnect battery ground cable.

•

Drain coolant.

1. Vacuum Hose

2. Air Intake Duct

3. PCV Hose

4. Injection Pipe

•

Release injection pipe clip.

•

Loosen the flare nut on the injection pump side.

•

Loosen the flare nut on the injection nozzle side,
disconnect and put a side the pipe.

5. Oil Level Gauge Guide Tube

•

Remove the fixing bolt and remove level gauge guide
tube.

6A1-8-1.tif

6A1-8-2.tif

Removal steps
1. Vacuum hose
2. Air intake duct
3. PCV hose
4. Injection pipe
5. Oil level gauge guide tube
6. Oil cooler water pipe (Oil

Cooler Model)

7. Inlet manifold

Installation steps
To install, follow the removal
steps in the reverse order.

4JB1/4JB1T/4JB1TC/4JG2 – ENGINE 6A1 – 9

6. Oil Cooler Water Pipe (Oil Cooler Model)

•

Remove the water pipe bracket bolt.

•

Remove the inlet manifold fixing nut.

7. Inlet Manifold

•

Remove the manifold fixing bolt and nut.

INSTALLATION

7. Inlet Manifold

•

Tighten the fixing bolts and nuts to the specified
torque.

Bolt & Nut

N∙m(kg∙m/lb∙ft)

19(1.9/14)

6. Oil Cooler Water Pipe (Oil Cooler Model)

•

Install the water pipe and tighten the manifold with
water pipe.

•

Tighten the pipe bracket bolt of cylinder head rear
side.

5. Oil Level Gauge Guide Tube

•

Install the guide tube and tighten the manifold with
guide tube.

4. Injection Pipe

•

Connect the injection pipe and tighten flare nut to the
specified torque.

Flare nut torque

N∙m(kg∙m/lb∙ft)

29(3.0/22)

•

Install the pipe clip to the original position.

3. PCV Hose

2. Air Intake Duct

1. Vacuum Hose

•

Connect the battery ground cable.

•

Pour coolant.

•

Start the engine and check coolant leakage.

6A1-9-1.tif

6A1-9-2.tif

6A1-9-3.tif

6A1 – 10 4JB1/4JB1T/4JB1TC/4JG2 - ENGINE

EXHAUST MANIFOLD

REMOVAL

Preparation:

•

Disconnect battery ground cable.

1. Vacuum Hose (Exhaust Brake Model)

•

Remove the vacuum actuator hose.

2. Front Exhaust Pipe Nut

•

Remove the fixing nuts from exhaust manifold side.

3. Front Exhaust Pipe Stay Bolt

4. Heat Protector

5. Exhaust Manifold

•

Remove the manifold bolt and nut, then remove the
manifold and gasket.

6A1-10-1.tif

6A1-10-2.tif

4JB1/4JB1T/4JB1TC/4JG2 – ENGINE 6A1 – 11

INSTALLATION

5. Exhaust Manifold

•

Tighten the fixing nuts and bolts to the specified
torque.

Manifold Bolt Torque

N∙m(kg∙m/lb∙ft)

26 (2.7/20)

4. Heat Protector

•

Remove the heat protector and tighten to the specified
torque.

Heat Protector Bolt Torque

N∙m(kg∙m/lb∙ft)

19 (1.9/14)

3. Front Exhaust Pipe Stay Bolt

•

Tighten the fixing bolts to the specified torque.

Stay Bolt Torque

N∙m(kg∙m/lb∙ft)

40 (4.1/30)

2. Front Exhaust Pipe Nut

•

Tighten the fixing nuts to the specified torque.

Without Exhaust Brake

N∙m(kg∙m/lb∙ft)

69 (7/51)

With Exhaust Brake

N∙m(kg∙m/lb∙ft)

69 (7/51)

1. Vacuum Hose (Exhaust Brake Model)

•

Install the two hose a vacuum actuator.

•

Connect battery ground cable.

•

Start the engine and check coolant leakage.