how to remove and install turbocharger assembly for JCB HP 2010 with ISUZU INT-Tier4 engine

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