Fuel System 6C-1

Fuel System
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .6C-2
A list of defective phenomena . . . . . . . . . . . . . .6C-7
Special tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-7
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . .6C-8
Fuel System Check . . . . . . . . . . . . . . . . . . . . . . 6C-9
Special tool. . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . .6C-16
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Fuel Filter Cartridge . . . . . . . . . . . . . . . . . . . . . .6C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Special tool. . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-25
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-25
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-26
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-27
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-30
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-31
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-31
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-33
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-36
Fuel Sedimenter Switch . . . . . . . . . . . . . . . . . . .6C-37
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Service Precautions . . . . . . . . . . . . . . . . . . . . .6C-38
Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-40
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-41
6C-2 Fuel System

Fuel System
Service Precautions Work procedure
Parts of the fuel system such as the internal part of the • The fuel opening must be quickly sealed when
fuel injector, holes and clearances that form passages removing the fuel pipe, injection pipe, fuel injector,
for fuel are finished to a very high degree of accuracy. fuel supply pump, and fuel rail.
They are therefore highly sensitive to foreign matter • The eyebolts and gasket must be stored in a clean
and the entry of foreign matter could cause damage to parts box with a lid to prevent adhesion of foreign
the fuel passage. Therefore, effective measures should matter.
be taken to prevent the entry of foreign matter. • Fuel leakage could cause fires. Therefore, after
If water removal agent is used in the fuel then it will finishing the work, wipe off the fuel that has leaked
absorb moisture in the light oil and may cause rust. out and make sure there is no fuel leakage after
Therefore, do not use water removal agent in the fuel starting the engine.
tank.
Explanations on functions and operation
Fuel system diagram

Legend
1. Fuel Rail 7. Vent Valve
2. Leak Off Pipe 8. Fuel Filler Cap
3. Fuel Injector 9. Fuel Level Sensor
4. Fuel Return Pipe 10. Fuel Filter With Sedimenter
5. Fuel Feed Pipe 11. Fuel Supply Pump
6. Fuel Tank

Caution:
Be careful foreign material does not into the fuel
system, because the precise fuel system is used.
 Fuel System 6C-3
Fuel rail

Legend
1. Flow Damper 3. Pressure Sensor
2. Pressure Limiter
6C-4 Fuel System
Fuel supply pump

Legend
1. Fuel Temperature Sensor 4. Camshaft Key
2. Fuel Rail Pressure Regulator 5. Camshaft Nut
3. High Pressure Piping
 Fuel System 6C-5
Fuel injector Fuel filter

Legend
1. Priming Pump
2. Cartridge
3. Sensor
4. Heater
5. Drain Plug

Functional check
Air bleeding
Legend
1. Terminal Stud
2. Part for Mounting The Leak Off Pipe
3. O-Ring
4. Part for Mounting The Injection Pipe
5. Parts Number
6. ID Code Plate

Legend
1. Priming Pump
2. Air Bleed Plug

1. Before starting the engine

a. Fit a tray below the fuel filter (below the air
bleed plug).
b. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
near the plug overflows.
6C-6 Fuel System
c. Tighten the plug, and operate the priming pump 2. Install the adapter.
more than 10 times until it is filled with fuel.
After waiting for approximately a minute, loosen Special tool
the plug and bleed out the air in the fuel filter. Fuel pressure/vacuum gauge adapter:
(This work must be repeated a minimum of EN-47667
three times until no more air comes out from the 3. Connect the gauge (1) with hose to the adapter
plug.) (5).
d. Tighten the plug firmly and wipe the fuel in the
surrounding area. Operate the priming pump Special tool
(10 to 15 times) till it is filled with fuel and then Fuel pressure/vacuum gauge assembly:
send fuel to the engine. J-44638
2. After starting the engine
a. Start the engine by rotating the starter without
depressing the accelerator pedal.
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly rotate the idling control knob clockwise
and maintain it for 3 minutes.
d. Fully depress the accelerator pedal and
increase the rotations to maximum. (Repeat
this operation several times)
e. Rotate the idling knob counterclockwise and
return to idling mode.

Caution:
If the air bleeding work is insufficient then it could lead
to faults in the engine. Therefore, the procedures after
starting the engine should always be implemented.

Water drain
A warning lamp will light up if water above the specified
volume collects in the sedimenter. In such cases, drain
out the water by performing the following operations:
• Set a container at the tip of the plastic hose.
• Loosen the drain plug.
• Operate the priming pump several times to
discharge the water.
• Tighten the drain plug after discharging the water. Legend
• Operate the priming pump several times and 1. Fuel Pressure/Vacuum Gauge Assembly
check for fuel leakage. 2. Fuel Pipe (Intake Side)
• Check that the warning lamp in the meter is off. 3. Fuel Pipe (Discharge Side)
4. Fuel Filter
Fuel system vacuum check 5. Fuel Pressure/Vacuum Gauge Adapter
Use this procedure to measure the vacuum (negative
4. Loosen the air bleeding plug on the supply pump.
pressure) discharge side the fuel system.
5. Use your hand to operate the fuel filter priming
Important: pump. Operate the pump until all the air has been
The fuel pressure/vacuum gauge assembly (gauge (1)) bled from the system.
and the fuel pressure/vacuum gauge adapter (adapter 6. Start the engine and allow it to idle.
(5)) must be cleaned before connect to the fuel line. 7. Note the gauge (1) reading. If the reading is
Otherwise, foreign material adherent to the tools may normal, go to Step 8. If the fuel vacuum is greater
damage the fuel supply pump. than the specified value, there is a problem in the
fuel system. Perform the procedures outlined
1. Disconnect the fuel hose from the fuel filter
below.
housing. (fuel supply pump side).
Standard fuel vacuum Less than 5 in Hg
• Replace the cartridge fuel filter element.
 Fuel System 6C-7
• Check the fuel delivery pipe. If it is clogged, it 10. Connect the fuel hose.
must be replaced. 11. Use your hand to operate the fuel filter priming
• Remove the fuel pipe at the fuel filter inlet. Use pump. Operate the pump until all the air has been
high-pressure air forced through the fuel pipe to bled from the system.
clean the fuel system. 12. Start the engine and allow it to idle.
Caution: 13. Inspect the fuel system for fuel leakage.
• Remove the fuel filler cap before applying high-
pressure air. A list of defective phenomena
• Do not perform this procedure if the fuel tank is • Problems with starting
nearly full (fuel approaching or flowing into the fuel
• Hunting during idling
filler neck). The forced air will spray fuel from the
fuel filler neck. • Insufficient horsepower
• Maximum engine speed is too low
8. Remove the gauge (1) and hose from the adapter
• Engine does not stop
(5).
• Exhaust gas is blue or black.
9. Remove the adapter (5).

Special tool
Illustration Tool Number/ Description

EN-47667
Fuel Pressure/Vacuum
Gauge Adapter

J-44638
Fuel Pressure/Vacuum
Gauge Assembly
6C-8 Fuel System
Trouble Shooting
Problems with starting

Condition Possible Cause Correction

Problems with starting Fuel tank is empty Fill the tank.
Air has entered the fuel system. Bleed the air.
Fuel line is clogged or damaged. Repair or replace the fuel line. Re-
Connection to the fuel line is loose. tighten the connection.
Fuel filter element is clogged. Replace the cartridge.
Fault in the feed pump Replace the fuel supply pump.
Regulating valve is open. Replace
Sticking of the fuel injector nozzle Replace the fuel injector.
Defective engine control system Diagnose the engine control
system.

Hunting during idling

Condition Possible Cause Correction

Hunting during idling Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel Repair or replace the fuel system.
system
Drops of water have entered the Replace the fuel.
fuel system.
Fuel filter element is clogged. Replace the fuel filter element
(cartridge).
Sticking of the fuel injector nozzle Replace the fuel injector.
Defective engine control system Diagnose the engine control
system.

Insufficient horsepower

Condition Possible Cause Correction

Insufficient horsepower Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel Repair or replace the fuel system.
system
Water mixes in the fuel system Replace the fuel.
Fuel filter element is clogged. Replace the element or the
cartridge.
Sticking of the fuel injector nozzle Replace the fuel injector.
Defective engine control system Diagnose the engine control
system.

Maximum engine speed is too low

Condition Possible Cause Correction

Maximum engine speed is too low Fuel line is clogged or damaged. Repair or replace the fuel line.
Defective engine control system Diagnose the engine control
system.
 Fuel System 6C-9
Engine does not stop

Condition Possible Cause Correction

Engine does not stop Defective engine control system Diagnose the engine control
system.

Exhaust gas is blue or black

Condition Possible Cause Correction

Exhaust gas is blue or black. Reduction in injection-valve Replace the fuel injector.
opening pressure or defective
atomizing status
Engine control system malfunction System diagnosis.

Fuel System Check • There is adequate fuel in the fuel tank.

Description • There is no air in the fuel line.
The common rail fuel system is comprised of two fuel Diagnostic Aids
Pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side • The fuel system from the fuel tank(s) to the fuel
between the fuel supply pump and the fuel injectors. supply pump is under a slight vacuum with the
Fuel is drawn from the fuel tank via a feed pump and engine running. As a result, air can enter the fuel
then pumped into the fuel rail by two plungers, all of system if these connections are not tight or if there
which are internal to the fuel supply pump. This high is a crack in one of the fuel hoses. Air in the fuel
pressure is regulated by the engine control module system will cause fuel rail pressure fluctuations
(ECM) using the fuel rail pressure (FRP) regulator especially at high engine speed and load.
dependant upon values from the FRP sensor attached • If the fuel tank is empty or near empty, air might be
to the fuel rail. In case of fuel rail overpressure, a allowed to go into the fuel system. With air in the
pressure limiter valve threaded into the fuel rail will fuel system, smooth flow of fuel into the supply
open to release overpressure and return fuel back to pump is interrupted. Perform bleeding of fuel
the fuel tank. system after refilling.
The Fuel System Check diagnostic table directs the
service technician to the appropriate fuel system Notice:
diagnosis. The diagnostic table assumes the following The Actual Fuel Rail Pressure on scan tool will only
conditions are met: update with the engine running or one time after the
key is cycled when the ignition has been turned OFF
• The batteries are completely charged.
for longer than 10 seconds.
• The engine cranking speed is normal.

Step Action Value(s) Yes No

1. Install a scan tool.
2. Turn ON the ignition, with the engine
OFF. Refer to
3. Observe the Diagnostic Trouble Code Applicable
1 —
(DTC) Information of the engine control Diagnosis Trouble
module with a scan tool. Code (DTC) in
Engine Control
Are any DTC(s) set? Section Go to Step 2
6C-10 Fuel System

Step Action Value(s) Yes No

1. Inspect the high pressure side between
the fuel supply pump and the fuel
injectors for fuel leakage. The following
components may contain an external
leak:
• Fuel supply pump
• Fuel rail
• Pressure limiter valve
• Flow damper valve
• Fuel rail pressure (FRP) sensor
• Fuel pipe between the fuel supply
pump and fuel rail
2 —
• Fuel pipe between the fuel rail and
fuel injectors
• Each fuel pipe sleeve nuts

Notice:
Fuel may leak under the cylinder head cover
from the inlet high pressure line. In such case,
the engine oil level will rise. Inspect for fuel in
the engine oil.

2. Repair any fuel system leaks as

necessary.

Did you find and correct the condition? Go to Step 18 Go to Step 3

1. Turn OFF the ignition.
2. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper
clamps.

Notice:
The fuel system from the fuel tank(s) to the
fuel supply pump is under a slight vacuum
with the engine running. As a result, air can
enter the fuel system if these connections are
not tight. Air in the fuel system will cause fuel
3 rail pressure fluctuations especially at high —
engine speed and load.

3. Pump the priming pump on the fuel filter

until it becomes firm .If there is a leak on
the suction side of the fuel system
between the priming pump and the fuel
supply pump, the priming pump will not
build up sufficient firmness and fuel
leakage may occur.
4. Repair any fuel system leaks as
necessary.
Did you find and correct the condition? Go to Step 18 Go to Step 4
 Fuel System 6C-11

Step Action Value(s) Yes No

1. Make sure the fuel tank(s) have adequate
fuel and the fuel quality is good (take a
sample).
2. Bleed the air from the fuel system as
necessary. Refer to Fuel System Air
Bleeding in this section.
3. Start the engine and let idle. If the engine 725psi
4 does not start, continue to crank. (5MPa)
4. Observe the Actual Fuel Rail Pressure
and Desired Fuel Rail Pressure
parameter with a scan tool.

Is the difference between the Actual Fuel Rail

Pressure and Desired Fuel Rail Pressure less
than the specified value? System OK Go to Step 5
1. Turn OFF the ignition.
2. Disconnect the in-line harness connector
(H-125) from the cylinder head cover
case.
3. Remove the rubber fuel hose from the
fuel filter housing (fuel supply pump side).
Use a pan to catch the fuel leakage from
the removed fuel line.

Important:
The fuel vacuum pump/pressure gauge
connector and the adapter hose must be
cleaned before connecting to the fuel line.
Otherwise, foreign material internal to the
tools line may damage the fuel supply pump.

4. Connect the suction side fuel pressure

adapter EN-47667 with fuel vacuum/
pressure gauge assembly J-44638 in
series with the filter housing and the
disconnected fuel hose. Ensure the
5 service tool and fuel line connections are 8 inHg
tight.
5. Bleed the fuel system by priming the
priming pump until it becomes firm, then
crank over the engine for a maximum of 5
seconds. Perform procedure three times.
6. Fully clamp off a fuel hose as close to the
fuel tank as possible (this will draw
vacuum on the fuel system). You can also
disconnect a fuel line and plug it.
7. Crank over the engine (for no longer than
15 seconds) while monitoring the fuel
pressure/vacuum gauge.

Notice:
Release the clamp or open the plug when the
gauge is likely to be more than 8 inHg during
the test.

Can a vacuum of at least the specified amount

be pulled on the fuel system? Go to Step 8 Go to Step 6
6C-12 Fuel System

Step Action Value(s) Yes No

1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper
clamps.
2. Draw fuel from the fuel tank at the fuel
line going to the fuel pickup tube to verify
6 a clean stream of fuel comes out (use the —
hand-held vacuum pump J-23738-A with
a clear hose or equivalent) This will
ensure the fuel pickup tube is not cracked
drawing air into the fuel line.
3. Repair as necessary.

Did you find and correct the condition? Go to Step 18 Go to Step 7

1. Replace the fuel filter cartridge. Refer to
Fuel Filter Cartridge Replacement in this
section.
7 2. Retest the fuel system vacuum test 8 inHg
described in Step 5.

Can a vacuum of at least the specified amount

be pulled on the fuel system? Go to Step 18 Go to Step 17
1. Unclamp or unplug the fuel line from Step
5 and reconnect the fuel line.
2. Prime the priming pump until firmness is
felt.
3. Crank over the engine for 5 seconds.
4. Repeat steps 2 and 3 three times to bleed
8 the fuel system. 5 inHg
5. Crank over the engine (for no longer than
15 seconds at a time while monitoring
the fuel pressure/vacuum gauge.

Does the vacuum/pressure gauge ever

indicate a larger than the specified value? Go to Step 9 Go to Step 10
1. Inspect the fuel lines between the fuel
supply pump and fuel tank for being
crushed or kinked.
2. Inspect the fuel cap for a plugged
condition.
9 3. Inspect inside the fuel tank (if possible) —
for any foreign material that may be
getting drawn into the fuel line pickup
causing a blocked condition.
4. Repair the condition as necessary.
Did you find and correct the condition? Go to Step 18 Go to Step 14
 Fuel System 6C-13

Step Action Value(s) Yes No

1. Turn OFF the ignition.
2. Make sure the in-line harness connector
(H-125) is disconnected from the cylinder
head cover case.
3. Remove the eyebolt from the cylinder
head that connects to the leak-off pipe.
4. Connect the fuel adapter J-45873-103
with hose assembly to the cylinder head.
Install the hose into a graduated cylinder
from the J-45873-100 kit.
5. Remove the eyebolt from the pressure
limiter valve that connects to the leak-off
pipe.
10 —
6. Connect the fuel adapter J-45873-105
with hose assembly to the pressure
limiter valve.
7. Crank over the engine for 10 seconds.
Make sure the batteries are fully charged
and the engine is cranking at normal
speed for each test.

Notice:
Perform this test three times and take the
average of the fuel return amount coming
from the cylinder head.

Is fuel leaking from the pressure limiter valve? Go to Step 15 Go to Step 11

Is the average fuel return coming from the
11 15ml
cylinder head less than the specified value? Go to Step 12 Go to Step 13
1. Remove each glow plug from the cylinder
head.
12 2. Inspect the tip of the plugs for wet fuel. —

Did you find wet fuel on any glow plug? Go to Step 16 Go to Step 17
1. Remove the cylinder head cover and
injector harness in order to connect the
fuel adapter J-45873-101 with hose
assembly to each injector leak-off port.
Refer to Fuel Injector Replacement in this
section.
2. Crank over the engine for 10 seconds.

Important:
13 Replacement injector must be programmed. 3ml

3. Replace the injector(s) that return more

fuel than the specified value. Refer to
Fuel Injector Replacement/Fuel Injector
Flow Rate Programming in this section.
4. Retest after replacement of the fuel
injector(s).

Did you complete the replacement? Go to Step 18 —

6C-14 Fuel System

Step Action Value(s) Yes No

Replace the fuel filter cartridge. Refer to Fuel
14 Filter Cartridge Replacement in this section. —
Did you complete the replacement? Go to Step 18 —
Replace the pressure limiter valve. Refer to
15 Fuel Rail Replacement in this section. —
Did you complete the replacement? Go to Step 18 —
Important: Replacement injector must be
programmed.
Replace the appropriate injector(s) that was
16 leaking fuel found at Step. Refer to Fuel —
Injector Replacement/Fuel Injector Flow Rate
Programming in this section.

Did you complete the replacement? Go to Step 18 —

Important: The fuel supply pump must be
timed to the engine and adjustment value
must be learned to the ECM.
17 Replace the fuel supply pump. Refer to Fuel —
Supply Pump Replacement/Fuel Supply
Pump Relearn Procedure in this section.

Did you complete the replacement? Go to Step 18 —

1. Reconnect all previously disconnected
harness connector(s) or components.
2. Turn OFF the ignition for 30 seconds.
3. Bleed the air from the fuel system. Refer
to Fuel System Air Bleeding in this
section.
4. Start the engine and let idle. 725psi
18
(5MPa)
5. Observe the Actual Fuel Rail Pressure
and Desired Fuel Rail Pressure
parameter with a scan tool.

Is the difference between the Actual Fuel Rail

Pressure and Desired Fuel Rail Pressure less
than the specified value? System OK Go to Step 1

Special tool
Illustration Tool Number/ Description Illustration Tool Number/ Description

EN-47667 J-44638
Fuel Pressure/Vacuum Fuel Pressure/Vacuum
Gauge Adapter Gauge Assembly
 Fuel System 6C-15

Illustration Tool Number/ Description

J-23738-A
Vacuum Pump

J-45873
Fuel Test Adapter Kit

.

J45873-100
Fuel Test Adapters
6C-16 Fuel System

Fuel Filter Assembly

Components

Legend
1. Filler Cap 4. Fuel Heater Connector
2. Fuel Sedimenter Connector 5. Bolt
3. Fuel Hose 6. Fuel Filter Assembly

Removal
1. Remove the filler cap.
2. Remove the fuel sedimenter and fuel heater
connector.
3. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
4. Remove the bolts for mounting the fuel filter.
5. Remove the fuel filter assembly.

Installation
1. Install the fuel filter assembly.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Install the fuel sedimenter and fuel heater
connector.
5. Install the filler cap.
6. Bleed out the air.
• Refer to “Fuel System”.
 Fuel System 6C-17

Fuel Filter Cartridge

Removal 2. Clean the cartridge mounting surface in the filter
body so that the cartridge can be seated securely.
1. Remove the cartridge using the filter wrench.
3. Coat a thin layer of engine oil on the O-ring in the
Special tool new cartridge.
Filter wrench: J-22700 4. To simplify air bleed, fill light oil on the new
2. Remove the sedimenter sensor. cartridge.
5. Tighten the cartridge until the O-ring touches the
sealing surface. During this process take adequate
care that the light oil that is inside does not flow
out.
6. Use the filter wrench and tighten rotating by 1/3 to
2/3.

Special tool
Filter wrench: J-22700

Legend
1. O-Ring
2. Cartridge
3. Sedimenter Sensor
4. Fuel Heater Connector

Installation
1. Assemble the sedimenter sensor in the new
cartridge.

Special tool
Illustration Tool Number/ Description

J-22700
Filter wrench
6C-18 Fuel System

Fuel Injector
Components

Legend
1. Fuel Injection Pipe Clip 8. EGR Valve Gasket
2. Fuel Injection Pipe 9. EGR Valve
3. Fuel Injector Leak-Off Pipe 10. EGR Valve Gasket
4. Fuel Injector 11. Cylinder Head Cover
5. Fuel Injector Clamp 12. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 13. Fuel Injector Terminal
7. EGR Adapter

The fuel system consists of many tiny holes and material into the fuel system or fuel injectors during the
spaces that allow the movement of fuel from one place removal and installation procedure.
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the Caution:
fuel injectors. To avoid electric shock;
The fuel injector is very sensitive to foreign material. Set the switch to the ‘OFF’ position and disconnect
Foreign material will result in fuel system breakdown. battery negative cable before checking or repairing the
Exercise great care not to allow the entry of foreign fuel injector, wiring or/and connectors.
 Fuel System 6C-19
Removal 6. Loosen the fuel injector harness bracket bolts.
Remove the inside connector and the harness
1. Remove the engine harness, the throttle position
bracket.
sensor, the EGR valve, the pressure sensor, and
all of the fuel injector connectors. 7. Remove the fuel injector leak-off pipe.
2. Remove the EGR valve and the EGR adapter. 8. Remove the lower cover.
3. Tape the EGR case holes shut to prevent the entry
of foreign material.

Legend
1. Harness Bracket
2. Harness Connector
Legend
3. Fuel Injector Terminal
1. EGR Adapter
4. Fuel Leak-Off Pipe
2. EGR Valve

4. Remove the cylinder head cover.

Legend
1. Cylinder Head Cover

5. Alternately loosen the fuel injector terminal nuts a

little at a time in sequence. Several loosening
cycles should be required before the nuts are
loose.
6C-20 Fuel System
9. Remove the fuel injection pipe clips and the Special tools
injection pipes. Fuel injector remover: EN-46720
Sliding hammer: J-23907

Legend
1. Fuel Injection Pipe Legend
2. Pipe Clip 1. Sliding Hammer
2. Remover
10. Loosen the fuel injector clamp fixing bolts and 3. Fuel Injector Assembly
remove the fuel injectors.
If the fuel injectors are difficult to remove, use the fuel 11. Mark each fuel injector with the number of the
injector remover. Install the fuel injector remover to the cylinder from which it was removed. Store the fuel
leak-off pipe attachment part on the fuel injector. Use a injectors in a safe place. Position the fuel injector
sliding hammer to force the fuel injector clamp off the so that the nozzle is protected.
fuel injector.
Caution:
Caution: • Do not tamper with the electromagnetic portion of
Do not remove the fuel injector sleeve. the fuel injector. Reduced electromagnetic function
will result in injector failure.
 Fuel System 6C-21
Recording Fuel Injector Flow Rate Information from
the QR plate on the replaced injector housing;
Record all numbers of replaced fuel injector's from QR
plate.

Legend
1. Gasket
2. Fuel Injector
3. Bolt
Legend 4. Fuel Injector Clamp
1. QR Plate
2. Fuel Injector Flow Rate 2. Apply molybdenum to the threads and seating
3. Fuel Injector surfaces of the clamp bolts.
3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
Installation 5. Apply a thin coat of engine oil to the outer surface
Important: of the fuel injector side sleeve nuts.
Install each of the fuel injectors on its original position. 6. Install the fuel injector pipes to the position shown
(the cylinder from which it was removed) in the illustration.
7. Use a spanner to carefully the sleeve nuts until the
1. Install a new gasket and O-ring to each of the fuel
fuel injector pipes contact the fuel injector and
injector clamps. Refer to the illustration.
common rail.
8. Tighten the fuel injection pipe clips to the specified
torque.
Tightening torque: 6 N m (52 lb in)
6C-22 Fuel System

Legend
1. Clamp Bolt
2. Sleeve Nut

11. Install the nozzle leak off pipes together with the
new gaskets. Tighten the pipes to the specified
torque.
Tightening torque: 12 N m (104 lb in)

Legend
1. Fuel Injection Pipe
1. Pipe Clip

9. Final tighten the injection clamp bolts to the

specified torque.
Tightening torque: 30 N m (22 lb ft)
10. Tighten the injection pipes to the specified torque.
Tightening torque: 44 N m (33 lb ft)

12. Install the fuel injector harness connectors. Work

from the inside out.
13. Install the harness bracket and tighten the bolts to
the specified torque.
Tightening torque: 48 N m (35 lb ft)
 Fuel System 6C-23

14. Install the fuel injector terminal nuts to the injector. Legend
15. Alternately tighten each nut 2 or 3 turns at a time 1. Cylinder Head Cover
until the specified torque is reached.
18. Install the gasket to the EGR valve and tighten the
Tightening torque: 2 N m (17 lb in) bolts to the specified torque.

Caution: Tightening torque: 24 N m (17 lb ft)

Do not overtighten the nuts. Damage to the terminal 19. Install the gasket to the EGR adapter and tighten
studs will result. the bolts to the specified torque.
Tightening torque: 24 N m (17 lb ft)

Legend
1. Fuel Injector Legend
2. Harness 1. EGR Adapter
3. Terminal Nut 2. EGR Valve Gasket
3. EGR Valve
16. Install the gasket to the cylinder head cover. 4. EGR Valve Gasket
17. Install the cylinder head cover and tighten the bolts
20. Attach the engine harness connectors. Each
to the specified torque.
composite connector should make a loud click
Tightening torque: 18 N m (13 lb ft) when it is securely attached.
6C-24 Fuel System
Before Programming the Fuel Injector Flow Rate 4. In the "Select Diagnostic Tool and Programming
Important: Process" screen, select the following menu.
DO NOT program the fuel injector flow rate unless you • Diagnostic tool "Pass-Thru".
are directed by a service procedure or you are directed • Select Programming Process "Reprogram
by a service bulletin. Programming the fuel injector at ECU".
any other time will not permanently correct a customers • ECU Location on the "Vehicle".
concern. Then, follow the SPS screen instructions.
Ensure the following conditions are met before 5. Ensure that ALL programming contents are
programming the ECM. entered correctly and were programmed
successfully by turning OFF the ignition for 30
• Vehicle system voltage
seconds.
- There is no charging system concern. All
6. Using the scan tool to check each programmed
charging system concerns must be repaired
fuel injector flow rate following this navigation:
before programming the ECM.
Diagnostics > (5) 2006 > Isuzu > NPR/NQR/NRR >
- Battery voltage is greater than 12 volts but less F0: Powertrain > (6) 5.2L L4 Diesel > Automatic or
than 16 volts. The battery must be charged Manual > F2: Special Functions > F5: Option
before programming the ECM if the battery Programming > F0: Injector Flow Rates.
voltage is low.
7. Start the engine and let idle.
- A battery charger is NOT connected to the
8. Inspect for a proper engine running condition and
vehicle's battery. Incorrect system voltage or
for no DTCs. Refer to the Diagnostic System
voltage fluctuations from a battery charger may
Check - Engine Control if needed.
cause programming failure or ECM damage.
- Turn OFF or disable and system that may put a
load on the vehicle's battery.
• Headlights
• Room lights
• Accessory equipment
• The ignition switch is in the proper position. DO
NOT change the position of the ignition switch
during the programming procedure, unless
instructed to do so.
• All tool connections are secure.
- RS-232
- The connection at the data link connector
(DLC) is secure.
- Voltage supply circuit
• DO NOT disturb the tool harness while
programming. If an interruption occurs during the
programming procedure, programming failure or
ECM damage may occur.
• Surrounding environment
- Surrounding temperature is more than 32 F
(0 C) but less than 122 F (50 C) during the
programming procedure. Excessively low or
high temperature may cause the programming
failure or ECM damage.
- Electromagnetic interference (EMI) on the tool
harness and ECM may cause the programming
failure or ECM damage.

Fuel Injector Flow Rate Programming Procedure

1. Connect the scan tool to the data link connector.
2. Connect the RS-232 to the scan tool and PC.
3. Start TIS 2000 and select the Service
Programming System (SPS).
 Fuel System 6C-25
Torque Specifications

Illustration Tool Number/ Description Illustration Tool Number/ Description

J-23907 EN-46720
Sliding hammer Fuel injector remover

)2
6C-26 Fuel System

Fuel Supply Pump

Components

Legend
1. Fuel Leak-Off Pipe 5. Bracket
2. Fuel Pipe 6. Bracket O-Ring
3. Fuel Supply Pump 7. Drive Gear
4. O-Ring 8. Oil Drain Adapter

The fuel system consists of many tiny holes and

spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
removal and installation procedure.

Important:
The Fuel supply pump must be timed to the engine and
adjustment value must be learned to the ECM.

Removal
1. Remove the intake pipe and the intake throttle
valve.
2. Remove the fuel pipe and fuel leak-off pipe. 3. Remove the fuel feed hose.
 Fuel System 6C-27
4. Disconnect the connector of fuel temperature
sensor and the fuel rail pressure regulator from the
fuel supply pump.
5. Remove the fuel supply pump attachment bolts
and nuts, then remove the fuel supply pump.

Notice:
One of the attachment bolt (1) secures the fuel supply
pump to the flywheel housing as denoted in the picture
below.

Legend
1. Fuel Supply Pump
2. O-Ring
3. Fuel Supply Pump Bracket

Installation
1. Install the O-ring to the fuel supply pump.
2. Install the pump to the bracket and tighten the 3
bolts to the specified torque.
6. Use a gear puller to remove the fuel supply pump
gear and the bracket O-ring. Tightening torque: 19 N m (14 lb ft)

Caution:
Take care not to twist the O-ring.

7. Loosen the 3 bolts holding the fuel supply pump

bracket. Remove the bracket and the O-ring.

Legend
1. Fuel Supply Pump
2. O-Ring
3. Fuel Supply Pump Bracket
6C-28 Fuel System
3. Align the fuel supply pump shaft key and gear. 5. Turn the crankshaft in the normal direction of
Install the gear and tighten the nut to the specified engine rotation until the No. 1 or No. 4 cylinder is
torque. at TDC on the compression stroke.
There is a round alignment mark on the gear Refer to the illustration.
(white paint).
Tightening torque: 64 N m (47 lb ft)

Notice:
There are 2 timing marks on the crankshaft pulley.
Legend Mark (1) is near the front cover and is used to bring the
1. Fuel Supply Pump 4HK1-TC engine to TDC.
2. Fuel Supply Pump Gear Mark (2) is not applicable to this engine.
3. Nut Be sure to use mark (1) when bringing the engine to
TDC.
4. Apply white paint to the top of the fuel supply pump
gear tooth directly above the stamped ‘O’ mark.
Refer to the illustration.

6. Remove the oil drain adapter.

7. Install the O-ring to the fuel supply pump.
8. Align the slits as shown in the illustration.
9. Insert the stud bolts into the guides and
temporarily tighten them.
 Fuel System 6C-29
Caution:
• If the stud bolts (cylinder block side) have been
loosened or replaced, apply Loctite 262 to the
recessed portion of the bolts.

Legend
1. Oil Drain Adapter
2. O-Ring

• Check that the round alignment mark (white paint) 12. Connect the fuel temperature sensor and the fuel
is positioned as shown in the illustration when rail pressure regulator connectors to the fuel
viewed from the plug hole. If necessary, reposition supply pump.
the gear. 13. Install the fuel feed hose.
• Tighten the stud bolts and the nuts to the specified 14. Install the throttle assembly.
torque. • Coat the fluid gasket and mount within 7
minutes.
Tightening torque nut: 50 N m (37 lb ft)
bolt: 76 N m (56 lb ft) Tightening torque: 24 N m (17 lb ft)
• Install the intake throttle valve chamber hose.

Legend
Legend
1. Plug Hole
1. Throttle Valve chamber
2. Alignment Mark
15. Install the fuel pipe and fuel leak-off pipe.
10. Apply a light coat of engine oil to the O-ring.
11. Install the oil drain adapter to the plug hole.
Tighten the bolt to the specified torque.
Tightening torque: 8 N m (69 lb in)
6C-30 Fuel System
Fuel Supply Pump Relearn Procedure 5. Observe the Supply Pump Status paremater with
The ECM gose through a fuel supply pump learn the scan tool. Confirm the scan tool indicates Not
procedure to fine tune the current supplied to the fuel Learn.
rail pressure (FRP) regurator. This learning process in 6. Start the engine and let idle until engine coolant
only performed when the engine is idling. temparature (ECT) reads 149 F (65 C) or higher
1. Install the scan tool. while observing Supply Pump Status parameter
with the scant tool. The scan tool changes status
2. Turn OFF the ignition for 30 seconds.
Not Lean > Tentative > Learning > Learned.
3. Turn ON the ignitioin, with the engine OFF.
7. If the ECM has correctly learned the fuel supply
4. Command the Supply Pump Learn Reset with the pump current adjustment, the Supply Pump Status
scan tool. parameter on the scan tool will indicate Learned.

Torque Specifications
 Fuel System 6C-31

Fuel Rail
Components

Legend
1. Fuel Leak Off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Fuel Rail
4. EGR Valve Gasket 9. Fuel Rail Bracket
5. EGR Adapter

Parts of the fuel system such as the internal part of the Removal
fuel injector, holes and clearances that form passages
1. Remove the air intake pipe.
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter • Disconnect the connector for the intake air
and the entry of foreign matter could cause damage to temperature sensor.
the fuel passage. Therefore, effective measures should 2. Remove the fuel leak off hose from the leak off
be taken to prevent the entry of foreign matter. pipe.
• Cover the removed fuel hose with a lid, keep it
facing upward and secure it using wire, etc.
6C-32 Fuel System
3. Disconnect the connecter of fuel rail pressure 6. Remove the injection pipe clip and remove the
sensor, and all the connectors. injection pipes.
4. Remove the EGR valve and the EGR adapter.
5. Tape the EGR case holes shut to prevent the entry
of foreign material.

Legend
1. EGR Adapter
2. EGR Valve

Legend
1. Fuel Injection Pipe
2. Pipe Clip

7. Remove the fuel pipe.

8. Remove the clip and the fuel leak off pipe.

Legend
1. Fuel Pipe
2. Fuel Leak-Off Pipe

9. Remove the fuel rail and the fuel rail bracket.

 Fuel System 6C-33
• Should not have the flow damper. Should
always have the fuel rail.
• Take care not to damage the connector unit of
the pressure sensor.

 

Legend
1. Fuel Rail
2. Fuel Pressure Sensor
3. Fuel Pressure Limiter
Legend
1. Fuel Rail Bracket
2. Fuel Rail Installation
1. Tighten the fuel rail bracket using the specified
mounting torque.
Disassembly
Tightening torque: 19 N m (14 lb ft)
1. Remove the fuel pressure limiter.
2. Tighten the fuel rail using the specified mounting
torque.
Tightening torque: 19 N m (14 lb ft)

 

Legend
1. Fuel Rail
2. Fuel Pressure Sensor
3. Fuel Pressure Limiter
Legend
1. Fuel Rail Bracket
Reassembly 2. Fuel Rail

1. Insatll the tuel pressure limiter.

Tightening torque: 172 N m (127 lb ft)
6C-34 Fuel System
3. Tighten the fuel leak off pipe (1) using the • Apply a thin coat of engine oil on the periphery
mounting eyebolt and the clip using the specified of the sleeve nut on the fuel injector side and
torque. assemble.
Tightening torque (2): 18 N m (13 lb ft)
(3): 12 N m (104 lb in)
(4): 8 N m (69 lb in)
(7): 6 N m (52 lb in)
4. Tighten the fuel pipe (5) using the mounting sleeve
nut and the specified torque.
Tightening torque (6): 44 N m (33 lb ft)
(8): 44 N m (33 lb ft)

Legend
5. Tighten the injection pipe and the clip using the 1. Fuel Injection Pipe
specified mounting torque. 2. Pipe Clip

Injection pipe sleeve nut 6. Install the gasket to the EGR valve and tighten the
Tightening torque: 44 N m (33 lb ft) bolts to the specified torque.

Injection pipe clip Tightening torque: 24 N m (17 lb ft)

Tightening torque: 6 N m (52 lb in) 7. Install the gasket to the EGR adapter and tighten
the bolts to the specified torque.
Tightening torque: 24 N m (17 lb ft)
 Fuel System 6C-35

Legend
1. EGR Adapter
2. EGR Valve Gasket
3. EGR Valve
4. EGR Valve Gasket

8. Install the air intake duct.

• Connect the connector for the intake air
temperature sensor.
6C-36 Fuel System
Torque Specifications
 Fuel System 6C-37

Fuel Sedimenter Switch

Inspection
1. Check that there is continuity between the switch
connector terminals when the float in the fuel
sedimenter is above the water drain line.
2. Turn on the ignition switch, remove the fuel
sedimenter connector, and connect the terminals
of the connectors on the harness side. Confirm
that the sedimenter warning lamp lights up.
If abnormalities are detected during the check, replace
the switch parts and carry out repairs in case of
defective connection between circuits or short circuits.

Legend
1. Sensor
2. Connector on The Vehicle Side
3. Harness
4. Drain Cock
6C-38 Fuel System

Fuel Tank
Service Precautions Fuel Tank Replacement
The fuel tank is mounted on the right frame rail and is Notice:
supported by two brackets. The tank is attached to the To prevent possible accident when working on fuel
bracket by a metal strap backed with a rubber cushion system, disconnect the vehicle battery negative (-)
strip. A vent valve is installed at the top of the fuel tank cable(s) and provide the appropriate fire fighting and
to relieve excess pressure. A drain plug is located in safety equipment in accordance with local fire and
the bottom of the tank for draining purposes. The fuel safety regulations.
tank identification tag is located next to the filler cap. Before removing the fuel tank to correct a leak, a
careful inspection of the tank should be made to
determine the actual source of the leak. “Seam leaks”
often turn out to be leaks at the filler neck, fuel line
connections, or at the tank sending unit seal. In such
cases, fuel runs down the side of the tank to the flanges
and drips off at points along the seam giving a false
indication of leaking seams. If careful inspection
reveals that the tank is actually leaking, remove the
tank for repairs as required.
A leaking fuel tank must be repaired or replaced
immediately. In addition to increased operating
expense, leaking fuel tanks represent a serious fire
hazard. No leakage is allowed anywhere in the fuel
system lines or tank.

Legend
1. Bracket 5. Filler Cap
2. Fuel Lines 6. Mounting Strap
3. Fuel Tank Unit 7. Drain Plug
4. Fuel Tank
 Fuel System 6C-39
Removal (Side Mounted Type) 6. Fuel tank from vehicle.
1. Battery negative cable. • Use a jack or suitable support.
2. Drain plug.
Installation (Side Mounted Type)
• Place a container under the drain plug to catch
the fuel. 1. Fuel tank onto the bracket.
3. Fuel lines. 2. Mounting strap with the rubber cushion strips.
4. Wires from the sending unit. Tightening torque: 30 N m (22 lb ft)
• On vehicles where the top of the tank is not 3. Fuel lines.
easily accessible, loosen the mounting strap
4. Wire to fuel tank unit.
enough to rotate the tank and disconnect the
fuel lines and wires. 5. Drain plug.
• Place a jack or suitable support under the fuel Tightening torque: 74 N m (55 lb ft)
tank.
6. Battery negative cable.
5. Nuts from the mounting strap stud bolts.

Legend
1. Filler Cap 6. Fuel Filler Hose
2. Fuel Line 7. Drain Plug
3. Fuel Line 8. Bracket
4. Fuel Tank 9. Breather Pipe
5. Fuel Tank Unit

Removal (Rear Mounted Type) 4. Wires from the sending unit.

1. Battery negative cable. 5. Remove the bolts of bracket from tank unit.
2. Drain plug. • Use a jack or suitable support.
• Place a container under the drain plug to catch Remove the bolts of frame from bracket.
the fuel. 6. Fuel tank from vehicle.
3. Fuel lines. • Use a jack or suitable support.
6C-40 Fuel System
Installation (Rear Mounted Type)
1. Temporary install the fuel tank to an attachment
position used jack suitable support.
2. Install the bracket.
• Tighten bolt of bracket frame side.
• Tighten bolt of bracket fuel tank side.
Tightening torque: 116 N m (86 lb ft)
3. Fuel lines.
4. Wire to fuel tank unit.
5. Drain plug.
6. Battery negative cable.

Fuel Tank Unit

The fuel tank unit is a float-controlled variable resistor
(rheostat). It is mounted on the top of the fuel tank and
has a float arm extending inside the tank. The position
of the float moves the float arm across the rheostat,
thus determining the amount of current sent to the fuel
gage in the vehicle. Some models use a protective top
to shield the top of the fuel tank unit.
If the fuel tank unit or the dash fuel gage has become
inoperative, the only remedy is to replace the
inoperative unit.
For checking or diagnosis of fuel tank unit, refer to
procedure under the heading of INSTRUMENTS AND
GAGES (SEC. 8D) in this manual.
For dash gage replacement, refer to applicable heading
under INSTRUMENTS AND GAGES (SEC. 8D) in this
manual.

Removal
1. Battery cable.
2. Wires from the top of the fuel tank unit.
3. Fuel tank unit.

Installation
1. Fuel tank unit into the fuel tank.
• Rotate the fuel tank (Round type) to the correct
position.
Tightening torque: 1.5 N m (13 lb in)
2. Wires to the fuel tank unit.
3. Battery cable.
 Fuel System 6C-41
Torque Specifications
Fuel tank (Side Mounted Type)

Fuel Tank (Rear Mounted Type)