Installation of Isuzu engine 4JJ1 Euro 4 N Series Radiator

         This article is about the installation of isuzu engine 4JJ1 Euro 4 N Series radiator

Installation
1. Be careful not to damage the radiator core with thefan blades. Install the left and right brackets of the radiator to the frame side bracket as shown in the diagram.
Frame side bracket and radiator left and right bracket Tightening torque:26 N-m (2.6 kg-m/19 lb-ft)
 ISUZU US-IDSS Diagnostic Service Truck Diagnostic System [06.2021]

Legend
1.Flange nut
2.Rubber
3.Stud bolt
4.Frame side bracket
5.Radiator side bracket
6.Washer


2. Install the intercooler.
Tightening torque:15N-m(1.5kg-m/11 lb-ft)
3. Install the ATF coolant pipe.(Smoother vehicles)
4. Install the fan guide bracket.
Refer to "Water Pump"in this section.
5. Install the coolant reserve tank hose to the radiator.
6. Install the radiator lower hose.
· Tighten the radiator hose clip.
Tightening torque:5 N-m(0.5kg-m/43 lb-in)
7. Install the radiator upper hose.
· Tighten the radiator hose clip.
Tightening torque:5 N-m(0.5kg-m/43 lbin)
8. Install the intake hose.
NOTE:
Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.
· Install the intake hose between the intercooler and throttle valve.
· Use a new hose clamp, align it with the marking.
Tightening torque:8 N.m(0.8 kgm/69 lbin)


· Mount the bracket for the intake duct.
Tightening torque:22.8 N-m(2.3 kgm/17 Ib-ft)
9. Connect the boost sensor harness connector and the ECM harness connector.
10. Refill the coolant.
11. Install the intake hose.
NOTE:
Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.
· Install the intake hose between the intercooler and turbocharger.
· Use a new hose clamp align it with the marking.
Tightening torque Intercooler side:8 N-m(0.8 kg-m/69 lb-in)
Turbocharger side:6.4 N.m (0.65 kg-m/56.4 lb-in)
NORMA W3 Clamp
8 Nm (0.8 kg-m/69 lb-in)
NORMA W1 Clamp
· Mount the bracket for the intake pipe.
Tightening torque:22.8 N-m(2.3kg-m/17 b-ft) Reference Coolant filing procedures (when replacing all of the coolant)
1. Check that the engine is cool.
2. Open the radiator cap.


WARNING:
Do not loosen or remove the radiator cap when the coolant is hot. Steam and boiling water can burst out from the radiator possibly causing burns or heat related injuries. When opening the radiator cap, place a folded thick cloth over the cap when the coolant is cooled, and turn it gradually to release the pressure before opening i
t.

5. Drain the coolant from the reserve tank.
6. Tighten the drain plugs for the radiator and engine.
7. Remove the air bleeder plug from the engine.
(Except NLS model)

Isuzu E-IDSS Diagnostic Service System [03.2021]

CAUTION:
· Fill slowly to prevent air from entering the system.
· For EGR coolers with air bleeder plugs, remove the EGR cooler air bleeder plug and refill with an amount of coolant equivalent to the level betweenthe remaining coolant and the radiator inlet. Then reattach the air bleeder plug.

10. While manually pressing the radiator upper hose several times to remove air from inside the hose, refill with an amount of coolant equivalent to thelevel between the remaining coolant and the filler neck.
11. Repeat the procedure above until the coolant level no longer decreases.
12. Close the radiator cap.

13. Fill the reserve tank with coolant until the MAX line, and then close the reserve tank cap.

Legend
1. Reserve tank
2. MAX line(upper limit)3. MIN line(lower limit)
14. Start and idle the engine.
CAUTION: Idle the engine for 5 minutes or more.
15. Stop the engine and refill with an amount of coolant equivalent to the level between the remaining coolant and the filler neck.
16. Close the radiator cap, turn OFF the heater fan and heat the engine by turning ON the warm up switch.
17. Ater the warm up switch shuts OFF, increase engine speed to around 2,000 r/min and continue this for 5 minutes once the needle of the engine coolant temperature gauge reaches the center.
18. With the engine idling, confirm that the thermostat is open by touching the radiator upper hose to see if it is warm.
CAUTION: Confirm this not only by checking the engine coolant temperature gauge and the warm air following from the heater, but also by touching the radiator upper hose to see if it is warm. If the radiator hose is not warm, return to step 17 of this procedure.

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19. Idle the engine for 5 minutes.
20. Stop the engine and refill with coolant up to thefiller neck once the engine has sufficiently cooled, refill the reserve tank with coolant up to the MAX line.
CAUTION:
The following moming, refill the reserve tank with coolant up to the MAX line if the coolant level has dropped.