EXHAUST SYSTEM 6F – 1

SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS

PAGE
Main Data and Specifications........................................................................................... 6F - 2
General Description .......................................................................................................... 6F - 3
Removal and Installation .................................................................................................. 6F - 4
Inspection and Repair ....................................................................................................... 6F - 6
General Description .......................................................................................................... 6F -7
EGR System Diagram........................................................................................................ 6F 9
Inspection .......................................................................................................................... 6F-11
EGR Cooler (4JA1TC/4JH1TC Euro-III model)................................................................. 6F-12
Turbocharger ..................................................................................................................... 6F -15
Main Data and Specifications....................................................................................... 6F -15
General Description .......................................................................................................... 6F -16
Inspection and Repair ....................................................................................................... 6F -17
Special Tools ..................................................................................................................... 6F -19
IHI Service Network ........................................................................................................... 6F -20
6F – 2 EXHAUST SYSTEM

MAIN DATA AND SPECIFICATIONS

Front pipe
Pipe outside diameter x thickness mm (in) 50.8 x 1.6 (2.0 x 0.063)
For EC model, catalitic converter is
combined to the front pipe.
Middle pipe
Pipe outside diameter x thickness mm (in) 50.8 x 1.6 (2.0 x 0.063)
Silencer & tail pipe
Type Circular section-shell construction
of double skin and end plates,
internal construction of baffles
and perforated tubes.
Tail pipe outside diameter x thickness mm (in) 50.8 x 1.6 (2.0 x 0.063)
Length mm (in) Approximately 1335 (52.6)
Mounting
Number of suspension points 4
Type Rubber
 EXHAUST SYSTEM 6F – 3

GENERAL DESCRIPTION

RTW86FLF000201

The exhaust pipe layout is described in the above illustration.

The catalytic coverter is installed between the turbocharger and the front pipe.
6F – 4 EXHAUST SYSTEM

REMOVAL AND INSTALLATION

RTW86FLF000101

Removal Steps
1. Rear hanger rubber 6. Front hanger rubber
2. Silencer front nut 7. Front pipe nut
3. Exhaust silencer 8. Exhaust pipe gasket
4. Silencer hanger rubber
5. Middle pipe nut
 EXHAUST SYSTEM 6F – 5

Important Operations – Installation

Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.

1. Front Pipe Nut

Connect the exhaust pipe to the catalytic converter.
Torque N⋅m (kg⋅m/lb⋅ft)
67 (6.8/49)

×4 only)
2. Middle pipe Nut (4×
Connect the middle pipe to the front pipe.
Torque N⋅m (kg⋅m/lb⋅ft)
43 (4.4/32)

3. Silencer Front Nut

Connect the silencer to the front or middle pipe.
Torque N⋅m (kg⋅m/lb⋅ft)
43 (4.4/32)
6F – 6 EXHAUST SYSTEM

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

Front Exhaust Pipe

Exhaust Silencer
Check the pipes for corrosion, cracking, damage or
misalignment and repair as required.
Check the rubber rings for deterioration or damage and repair
as required.
Catalytic Converter
1. Inspect outside the catalytic converter for any hitting mark.
2. Visual check inside the catalytic converter for crack or break
converter element.
3. If find any problem during the inspection, replace the
catalytic converter assembly.
 EXHAUST SYSTEM 6F – 7

GENERAL DESCRIPTION
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.

4JA1T(L):
The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to
signals from various sensors.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.

RTW46ELF001201
6F – 8 EXHAUST SYSTEM

4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail.

RTW46ELF001101
 EXHAUST SYSTEM 6F – 9

EGR SYSTEM DIAGRAM 4JA1T (L)

RTW46AMF000301

EGR System Operation

Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up.
• Inspection point (Engine RPM)

RPM Idling 900 ∼ 960 2000 3250

Engine Front Side VSV-1 ON ON ON OFF
Engine Rear Side VSV-2 ON OFF ON OFF

ON means VSV should receive signal to move EGR valve.

OFF means VSV shouldn’t receive signal to move EGR valve.
6F – 10 EXHAUST SYSTEM

4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to “Engine driveability and
emissions” section for detail.

RTW46EMF000701
 EXHAUST SYSTEM 6F – 11

INSPECTION
4JA1T(L)
Vacuum switch valve (VSV)
Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance Ω at 20°C
37 ~ 44

If the resistance is not within specification, replace it.

EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.

Negative Pressure

Less then 180 mmHg Not operation

More than 240 mmHg Operation

4JA1TC/4JH1TC
EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance Ω at 20°C
14

If the resistance is not within specification, replace it.

RTW46ESH000301

EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.

Negative Pressure 4JH1TC

Less than 250 mmHg Not operation

More than 300 mmHg Operation

Negative Pressure 4JA1TC

Less than 100 mmHg Not operation

More than 170 mmHg Operation
6F – 12 EXHAUST SYSTEM

EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL)

REMOVAL AND INSTALLATION

RTW46EMF000201

Removal Steps
1. Bolt 7. EGR Pipe Assembly
2. Gasket 8. Gasket
3. Bolt 9. Bolt
4. Gasket 10. EGR Cooler Assembly
5. Bolt 11. Gasket
6. Bolt 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
 EXHAUST SYSTEM 6F – 13

RTW46EMF000901

Installation steps
1. EGR Cooler Adapter 8. Bolt
2. Gasket 9. Gasket
3. EGR Cooler Assembly 10. EGR Valve Assembly
4. Gasket 11. Bolt
5. Bolt 12. EXH Manifold
6. EGR Pipe Assembly 13. Gasket
7. Bolt 14. Bolt
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)
 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.
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.
 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

RTW86FSH000101

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.
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.
Wheel Shaft End Play mm (in)
Standard Limit
0.03 - 0.06
0.09 (0.004)
(0.001 - 0.002)

150RY00034

Wheel Shaft and Bearing Clearance

Use a dial indicator to measure the wheel shaft and
bearing clearance.
Wheel Shaft and Bearing Clearance mm (in)
Standard Limit
0.056 - 0.127
0.127 (0.0050)
(0.0022 - 0.0050)

150RY00036
 EXHAUST SYSTEM 6F – 19

SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME

5-8840-0075-0 Pressure Gauge

901RX00143
6F – 20 EXHAUST SYSTEM

IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger
Service Facility.

HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430

CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s Republic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN

TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO

THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH

MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257

INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT