Introduces Removaland of the Air Control Valve

          This article mainly introduces Removaland  of the  Air Control Valve

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1. Disconnect the Original Equipment Manufacturer
(OEM) hose assembly from inlet connection (5) ofair control valve assembly (4). Refer to the OEM for the correct procedure.
2. Disconnect harness assembly(1) from air control valve assembly(4).
3. loosen clamp(3) from hose assembly(2).
4. Loosen hose clamp(7) for tube assembly(6).
5. Disconnect tube assembly(6) from air control valve assembly(4).
6. Remove bolt (8) from bracket(9). Remove remaining bolt and remove air control valve assembly(4) from hose assembly (2).

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7. If necessary, follow Step 7.a through Step 7.e to disassemble air control valve assembly(4).
a. Place the air control valve assembly(4) in a suitable support.
b. Make temporary marks on elbow connection
(10), connection(17), and air control valve assembly(4) for installation purposes.
c. Remove bolts(16) and remove elbow connection(10) and connection(17) from air control valve assembly(4).
d. Remove O-ring seal(11)(not shown) and O-ring seal(15)(not shown).
e. If necessary, mark temporary marks on elbow connection(14) and connection(17).
Loosen locking nut(13)(not shown). Removeelbow connection(14) from connection(17).
Remove O-ring seal(12)(not shown).
Installation Procedure
1. Ensure that all components of the air control valve assembly are free from wear, damage,
or restriction.

2. If necessary, follow Step 2.a through Step2.e to assemble air control valve assembly(4).
a. Place the air control valve assembly(4) ina suitable support.
b. Install a new O-ring seal(11)(not shown) and new O-ring seal(15)(not shown) to the recesses of elbow connection(10) and connection(17). Ensure that the O-ring seals are correctly seated into the recesses.
C. Align elbow connection(10) and connection
(17) with the temporary marks on air control valve assembly(4).
d. Install bolts(16) to connection(17) and elbow connection(10). Tighten the bolts to a torque of
28N·m(248 lbin).
e. If necessary, install a new O-ring seal(12)(not shown) to elbow connection(14). Install the elbow connection to connection(17). Align the elbow connection with the temporary marks.
Tighten locking nut (13)(not shown) to a torque of 30N'm (266 lbin).

                                        

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3. Install air control valve assembly(4) into hose assembly(2).
4. Position bracket(9) onto air control valve assembly(4) and install bolts (8). Tighten the bolts to a torque of 28 N-m (248 lb in). Ensure that thebracket is not strained as the bolt is tightened.
5. Tighten clamp (3) for hose assembly (2) to a torque of 11 N-m (97 lb in).
6. Connect tube assembly(6) to air control valve assembly(4). Tighten hose clamp(7) to a torque of 4.5N-m (40 lb in).
Tighten tube nut for tube assembly(6) to a toque of 30 N·m (266 lb in).
7. Connect harness assembly(1) to air control valve assembly(4).
8. Connect the OEM hose assembly to inlet connection(5) of air control valve assembly(4). Refer to the OEM for the correct procedure and torque value.

Introduces Perkins 2806F Engine Solenoid Valve(Exhaust Balance)-Remove

 This article mainly introduces Perkins 2806F Engine Solenoid Valve(Exhaust
Balance)-Remove

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1. Disconnect harness assembly(1) from harness assembly(2).
2. Disconnect tube assembly(4) from balance valve
(5).
3. Remove bolt (4) and bolt (8) for tube assembly (7).
4. Disconnect tube assembly(7) from balance valve
(5).
5. Remove bolt (6) from balance valve(5). Remove the balance valve from the bracket.

6. If necessary, follow Step 6.a through Step 6.d to disassemble balance valve(5).
a. Place the assembly of balance valve(5) in a suitable support.
b. Make temporary marks on elbow connection
(14) and balance valve(5) for installation purposes.
C. Loosen lock nut(13) and remove elbow connection(14) balance valve(5). RemoveO-
ring seal(12).
d. Remove adapter(10) from balance valve(5).
Remove O-ring seal(11).

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7. If necessary, follow Step 7.a through Step 7.b to remove tube assembly(4).
a. Remove bolt (16) from the tube clip for tube assembly(4).
b. Disconnect tube assembly(4) from adapter
(15). Remove the tube assembly.

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8. Ifnecessary, follow Step 8.a through Step 8. cto remove tube assembly(7).
a. Remove bolt(17) and bolt (18) from the tube clip for tube assembly(7). Ensure that the tube clips are not damaged as the bolts are removed.
b. Disconnect tube nut(20) for tube assembly(7)
from waste gate actuator(19).
c. Remove tube assembly(7).

Perkins 2806F EngineTurbocharger-Install

 
          This article mainly introduces Perkins 2806F EngineTurbocharger-Install 

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NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure all the components of the turbocharger are free from wear, damage, and restriction. Replace any component that is worn, damaged, or not free from restriction.

llustra6on 5390d0rr8502. Ifnecessary, follow Step 2.a through Step 2. fto install tube assembly(8) and tube assembly(15).a. Install a new O-ing seal(23)(not shown) to the elbow connection for tube assembly(8). Ensure that the O-ring seal is correctly seated into the recess of the elbow connection.
b. Install tube assembly (8) and hand tighten tube nut(24). Install bolts(20)(not shown) hand tight. Ensure that O-ring seal (23)(not shown) is not dislodged as the tube assembly is installed.c. Install a new O-fing seal(22)(not shown) to the elbow connection for tube assembly (15).
Ensure that the O-ring seal is correctly seated into the recess if the elbow connection.
d. Install tube assembly(15). Install bolts(21) and hand tighten.
e. Tightening of bolts(21), bolt (20)(not shown), and tube nut(24) will be required after the turbocharger has been installed.
f. For a turbocharger that is already installed, tighten bols (21), bolt(20)(not shown), and tube nut(24) as follows: Tighten bols (21) to a torque of47 N-m
(35 lbft).
Tighten bolt (20)(not shown) to a torque of
47N·m (35 ib ft).
Tighten tube nut (24) to a torque of65N-m
(48 lbft).

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3. If necessary, follow Step 3.a through Step 3.b to install studs (19) to exhaust manifold (16).
a. Apply Tooling (A) to the threads of new studs
(19).
b. install studs(19) to exhaust manifold(16).
Ensure that the studs are correctly orientated.
Tighten the studs to a torque of 18N-m
(159lb in).
4. Attach a suitable lifting device to turbocharger(7).
The weight of the turbocharger is approximately
30kg (66Ib).
5. Install a new gasket(17)(not shown) onto the exhaust manifold. Ensure that the gasketis correctly orientated.
6. Use the lifting device to position turbocharger(7)
onto exhaust manifold(16).
7. Install nuts(18) to turbocharger(7) hand tight.
8. Install a new gasket(13)(not shown) between tube assembly(15) and turbocharger(7).
9. Install Allen head bolts(14) to tube assembly(15)
hand tight.
10. Install a new gasket(10)(not shown) to tube assembly (8). Install Alen head bolts (9) to the tube assembly hand tight.
11. Tighten nuts(18) to a torque of 55 N-m(41 b ft).
12. Tighten Allen head bolts(14) to a torque of
25N-m(221lbin).
13. Tighten Alen head bolts (9) to a torque of25N-m
(221lbin).

14. Iftube assembly (8) and tube assembly(15) had been removed, follow Step through Step to tightenbolts (21), bolt(20)(not shown), and tube nut(24).
a. Tighten bolts (21) to a torque of 47 N-m
(35 lb ft).
b. Tighten bolt (20)(not shown) to a torque of
47Nm(35lb f).
c. Tighten tube nut(24) to a torque of65Nm
(48 b ft)

15. Connect inlet hose(6) to the inlet of turbocharger
(7). Refer to Disassembly and Assembly, Air Cleaner Housing-Remove and Install for the correct procedure.
16. Install a new O-ring seal(2)(not shown). Position elbow connection (3) onto turbocharger (7). Install V-band damp(1). Ensure that the O-ring seal is not dislodged as the elbow and V-band clamp are installed.
17. Follow Step 17.a through Step 17.b to tightenV-
band clamp(1).
a. Tighten V-band clamp(1) on the turbocharger to a torque of 8.5N-m (75 ib in).
b. Lightly tap V-band clamp(1) with a soft faced hammer to seat the V-band clamp. Again, tighten the V-band clamp to a torque of 8.5N-m
(75 b in). Repeat this Step 17.b until the V-band clamp are correctly seated onto the turbocharger.
18. Install a new V-band clamp(4) and connect exhaust connection(5) to turbocharger (7).F ollow Step 18.a through Step 18.b to tighten the V-band clamp.
a. Tighten V-band clamp(4) on the turbocharger to a torque of 8.5N-m (75 lb in).
Note: Ensure that the flexible exhaust section is not strained and the flexible exhaust remains in original alignment.
b. Lightly tap V-band clamp(4) with a soft faced hammer to seat the V-band clamp. Again, tighten the V-band clamp to a torque of9N-m
(80lb in). Repeat this Step 18.b until the V-band clamp are correctly seated onto the
14. If tube assembly(8) and tube assembly(15) had been removed, follow Step through Step to tightenbolts(21), bolt (20)(not shown), and tube nut(24).
a. Tighten bolts(21) to a torque of 47N-m
(35 Ib ft).
b. Tighten bolt(20)(not shown) to a torque of
47N·m(35 Ib ft).
c. Tighten tube nut(24) to a torque of65N-m
(48Ib ft).

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Perkins 2806F Engine Turbocharger-Remove

       This article mainly introduces  Perkins 2806F Engine   Turbocharger-Remove

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NOTICE Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations and mandates.
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

1. Disconnect inlet hose(6) from the inlet of turbocharger(7). Refer to Disassembly and Assembly, Air Cleaner Housing-Remove and Install for the correct procedure.
2. Loosen V-band clamp(1) and disconnect elbow connection(3) from turbocharger(7). Remove O-
ring seal(2)(not shown).
3. Loosen V-band clamp (4) and disconnect exhaust connection(5) from turbocharger(7).

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1. Remove Allen head bolts(9) from tube assembly
(8). Position the tube assembly away from turbocharger(7). Remove gasket(10)(not shown).
2. Disconnect tube assembly (12) from wastegate actuator(11). Position the tube assembly away from turbocharger(7).
3. Remove Allen head bolts(14) from tube assembly
(15).
4. Attach a suitable lifting device to turbocharger(7).
The weight of the turbocharger is approximately
30kg(66Ib).
5. Remove nuts(18) from turbocharger(7).
6. Use the lifting device to remove turbocharger(7)
from the exhaust manifold and coupling (16).
Remove gasket(17)(not shown).
7. Remove gasket(13)(not shown).
8. If necessary, remove studs(19) from exhaust manifold(16).

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9. If necessary, follow Step 9.a through Step 9. cto remove tube assembly (8) and tube assembly
(15).
a. Remove bolts (21) fromtube assembly(15).
Remove the tube assembly. Remove O-ring seal (22)(not shown).
b. Remove bolt(20)(not shown) from the clip for tube assembly(8).
c. Disconnect tube nut(24) for tube assembly(8).
Remove the tube assembly. Remove O-ring seal(23)(not shown).

 

Introduces Perkins 2806F Engine Air Cleaner-Remove and Install

   This article mainly Introduces Perkins 2806F Engine Air Cleaner-Remove and Install

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Removal Procedure
.NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

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1. For the location of the assembly of air cleaner(5).
Refer to Original Equipment Manufacturer (OEM)
for the correct location.
2. Loosen hose clamp(11) for hose assembly(12).
3. Attach a suitable lifting device to support the weight of air cleaner assembly (5). The weight of the air cleaner is approximately 23kg (51 lb).
4. Remove bolts (6) from air cleaner(5).
5. Use the suitable lifting device to remove air cleaner assembly(7) from the OEM bracket and the turbocharger.
6. If necessary, follow Step 6.a through Step 6.f to disassemble the assembly of air cleaner(5).
a. Position air cleaner (5) onto a suitable support.
b. Loosen clamp(2) and remove pre-cleaner(1)
from expansion adapter(3).
c. Loosen clamp(4) and remove expansion adapter(3).
d. Loosen hose clamps(11) for hose assembly
(10). Remove the hose assembly from tube assembly(9).
e. If necessary, remove indicator (10) from tube assembly(9).
f. Loosen hose clamps(7) for hose assembly(8). Remove the hose assembly from air cleaner(5)
and tube assembly(9).

Installation Procedure         

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2. If necessary, follow Step 2.a through Step 2. ito assemble the assembly of air cleaner(5).
a. Position air cleaner(5) onto a suitable support.
b. Apply Tooling (A) to hose assembly(8) and hose assembly(12).
c. Install hose assembly(8) onto air cleaner(5).
Ensure hose clamps (7) are correctly orientated.d. Install tube assembly (9) to hose assembly(8).
Ensure that the tube assembly is correctly orientated. Tighten the hose clamps to a torque of 8N-m(71lb in).
e. Installindicator(10) to tube assembly(9).
Securely tighten the indicator.
f. Install hose assembly(10) to tube assembly(9).
Ensure hose clamps(11) are correcty orientated. Tighten the hose clamp to a torque of 8N-m(71ib in).
g. Install expansion adapter (3) onto air cleaner
(5). Ensure clamp(4) is correctly orientated and seated onto the air cleaner. Securely tighten the clamp.
h. Install pre-cleaner(1) to expansion adapter(3).
Securely tighten clamp(2).
i. If air cleaner(5) has been disassembled, hose clamps(11) will need tightening after the air cleaner assembly has been installed.
3. Attach a suitable lifting device to support the weight of air cleaner assembly(5). The weight of the air cleaner is approximately 23kg(51 lb).
4. Use the suitable lifting device to install air cleaner assembly(7) onto the OEM bracket and the turbocharger.
5. Install bolts (6) to air cleaner(5) and the OEM bracket. Tighten the bolts, refer to the OEM for the correct tightening value.
6. Tighten hose clamp(11) for hose assembly(12) to a torque of8 N-m (71 lb in).
7. If necessary, replace air cleaner element for air cleaner assembly(5). Refer to Operation and Maintenance Manual, Engine Air Cleaner Element
-Replace for the correct procedure.

Introduces Install of the Isuzu Engine 4JJ1 Euro 4 N Series common Rail

     This article mainly introduces Install
of the Isuzu   Engine 4JJ1 Euro 4 N Series common Rail

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  1. Install the space rubber, common rail bracket, and common rail, and tighten them at the specified torque.
Tightening torque:25 N-m(2.5kgm/18 b-t)
2. Install the injection pipe and tighten the sleeve nut
(1) at the specified torque.
Tightening torque:25 Nm (2.5 kgm/18 lbt)

3. Install the harness connector of the fuel pressure sensor.
4. Connect the fuel hose(1).

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5. Install the fuel feed pipe(1) and tighten the sleeve nut at the specified torque.
Tightening torque:44 N.m(4.5kgm/33 bt)

6. Install the fuel leak-off pipe(1), and tighten the ayebolt at he specied torque. aC gml e Tightening torque:10 N-m(1.0kg-m/87 lb-in)

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7. Install the engine oil level gauge and guide tube, and tighten the fixing bolt at the specified torque.
· Apply engine oil to the O-ring of the guide tube.
Tightening torque:25 N-m(2.5kg-m/18 ib-ft)
8. Install the left side noise cover.
9. Install the dropping register harness connector.
10. Install the air duct.
NOTE: Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.
. Install the air duct between air cleaner and turbocharger.
· Use a new hose clamp, align it with the marking.
Tightening torque Air cleaner 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 kgm/69 b-in)
NORMA W1 Clamp
11. Install the air intake duct and hose.
List of Tightening Torques

NOTE: Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.
· Install the duct and hose between the intake throttle valve and intercooler.
· Use a new hose clamp, align it with the marking Tightening torque:8N-m (0.8kg-m/69 lb in)
12. Connect the connector of the boost sensor.

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