How to install an Isuzu engine assembly

Installation

1.Installthe engine assembly to the vehicle.

·Position engine mountings by using hoist.

2.Install the support rubber.

·After    all    fixing    bolts(left:two    bolts,right:two bolts)

were   inserted   to   every    holes,and   engine assembly   and   tighten   fixing   bolts   to   the specified torque

Tightening torque:    48 Nm(4.9 kg m/351b·ft)

 

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·P/S  pump  lock  bolt  loose,adjust  belt  tension with adjust belt.

Tightening torque

Idler lock nut:             27 Nm(2.8 kg·m/20 Ib·ft)

4.Install  the  radiator.

Refer to "Radiator"in Section 6B Engine Cooling.

5.Connect the vacuum hose from the vacuum pump.

6.Connect the ECM connector and clip.

7.Connect the fuel  hose.

·Connect the fuel inlet hose and fuel return hose to fuel supply pump.

8.Install the air intake pipe and hoses.

·Install the  pipe  and  hoses  between  the  intake throttle valve and intercooler.

·Use   a   new   hose   clamp,align   it   with    the marking,and tighten it at the specified torque.

Tightening torque

Clamp:                        8.0Nm(0.8  kg-m/71  Ib-in)

·Fix the air intake pipe to the bracket.

Tightening torque:    20  Nm(2.0  kg·m/177.5Ib-in)

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11.Install the air duct and PCV hose.

Tightening torque      Air cleaner side:

Clamp:                        6.4 Nm(0.65 kg·m/56.4  Ib-in)

Turbocharger side:

8.0 Nm(0.8 kg·m/71 Ib·in)

 

 

 

9.Connect    the    boost    sensor    connector.(Euro4 specification)

 

Legend

1.Boost  sensor  connector

10.Install the air intake pipe and hoses.

·Install   the    pipe    and    hoses    between    the turbocharger and intercooler.

·Use   a   new   hose   clamp,align   it   with    the marking,and tighten it at the specified torque.

Tightening torque

Clamp:                        8.0 N·m(0.8 kg m/71 Ib-in)

·Fix the air intake pipe to the bracket.

Tightening torque:    20 N·m(2.0 kg-m/177.5 Ibin)

 

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11.Install the air duct and PCV hose.

Tightening torque      Air cleaner side:

Clamp:                        6.4 Nm(0.65 kg·m/56.4  Ib-in)

Turbocharger side:

8.0 Nm(0.8 kg·m/71 Ib·in)

 

 

 

12.Connect the  heater  hose.

 

13.Install  the  transmission.

Refer to "Manual Transmission"in Section 7B.

14.Install the front exhaust pipe and exhaust brake.     Refer  to   "Exhaust  Pipe"and  "Exhaust  Brake"in Section 6F,Engine Exhaust.

15.Connect the engine ground cable from the frame.

16.Connect the B terminal from the starter motor

17.Installthe  cab.(Non-tlt  cab  model  only) Refer to "FRAME AND CAB"Section 2.

18.Refill the engine coolant.

19.Connect the battery cable negative terminal.