Page 1345 of 6020
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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Page 1346 of 6020
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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Page 1347 of 6020
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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Page 1348 of 6020
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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Page 1349 of 6020
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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Page 1350 of 6020

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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Page 1351 of 6020
6F – 18 EXHAUST SYSTEM
Wheel Shaft End Play
Use a dial indicator to measure the wheel shaft end play.
Apply a force of 1.2 kg (2.6 lb/11.8N) alternately to the
compressor wheel end and the turbine wheel end.
W heel Shaft End Play mm (in)
Standard Limit
0.03 - 0.06
(0.001 - 0.002) 0.09 (0.004)
150RY00034
Wheel Shaft and Bearing Clearance
Use a dial indicator to measure the wheel shaft and
bearing clearance.
W heel Shaft and Bearing Clearance mm (in)
Standard Limit
0.056 - 0.127
(0.0022 - 0.0050) 0.127 (0.0050)
150RY00036
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Page 1352 of 6020
EXHAUST SYSTEM 6F – 19
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
901RX00143 5-8840-0075-0 Pressure
Gauge
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