Fuel inspection (4JJ1 without DPD) - CITEC

Fuel inspection (4JJ1 without DPD)

1. Fuel safety information

Caution

Including the inside of the injector, the holes and gaps that are the fuel paths for the fuel system havean extremely precise finish.

Because there is a possibility of damage if foreign material enters, cap or cover after removing parts,etc., to thoroughly prevent foreign material from entering.

Add a cleaning fluid to the steam cleaner and thoroughly clean the sensor, common rail (fuel rail), andsupply pump areas.

Completely remove moisture with an air blower.

Verify that all foreign material has been completely removed before starting the procedure.

After replacing the various sensors, use the scan tool to verify that the trouble code is cleared andthat the sensors are operating normally.

Because fuel leakage may lead to fire, wipe off the leaked fuel after completing the work and after theinspection, and be sure to check for fuel leaks after starting the engine.

2. Fuel vehicle inspection

1) Start the engine.

2) Inspect the fuel system for loose connections.

Note

Inspect for fuel leakage.

Fuel air bleed (4JJ1 without DPD)

1. Fuel air bleed

1) Open the engine hood.

2) Press the priming pump until it becomes hard.

Caution

Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.

Legend

Priming pump1. Fuel filter with sedimenter2.

Fuel drain water (4JJ1 without DPD)

1. Fuel drain water

If the warning light illuminates, refer to the following procedure to drain the water.

Caution

If the warning light frequently illuminates, drain the fuel in the fuel tank, then perform the work.

When draining the fuel from the fuel tank, make sure to stop the engine.

Make sure that no flammable objects are around the container when draining the fuel.

1) Prepare pan.

2) Install the clear hose to the drain plug on the fuel filter.

Note

Place the container at the end of the hose attached to the drain plug.

3) Loosen the drain plug to drain moisture and deposits.

4) Push the priming pump several times to check for fuel leakage.

5) Tighten the drain plug.

Tightening torque: 1.0 N・m 0.1 kgf・m / 9 lb・in

6) Turn ON the ignition switch for 15 seconds.

7) Confirm that the warning light turns OFF.

Common rail (fuel rail) removal (4JJ1 without DPD)

1. Component views

Common rail (fuel rail)

Part name

Bolt1. Vacuum pipe2. Common rail (fuel rail) bracket3. Bolt4. Common rail (fuel rail)5.

Tightening torque

1: 25 N・m 2.5 kgf・m / 18 lb・ft

4: 25 N・m 2.5 kgf・m / 18 lb・ft

2. Preliminary and post procedures

1. Preliminary procedures


2) Disconnect the battery cable from the battery negative terminal.

Caution

After turning the ignition switch (power mode for models with the passive entry and start system)OFF, do not disconnect the battery cable within 1 minute.

The ECM may malfunction if the battery cable is disconnected within 1 minute.

If the battery cable is disconnected, perform the following settings after connecting the batterynegative terminal.

Steering angle sensor settingSetting for front door power window switch with AUTO UP/AUTO DOWN function

3) Raise the vehicle.

3. Starter motor removal

Refer to "1.Engine 1J.Electrical(4JJ1 without DPD) starter motor removal".

4. Fuel feed pipe removal

1) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).

Caution

Cover the exposed section to prevent the intrusion of foreign material.

Legend

Fuel feed pipe1.

5. Fuel hose disconnect

1) Disconnect the fuel feed hose from the fuel supply pump.

2) Disconnect the fuel return hose from the fuel leak-off pipe.

Legend

Fuel feed hose1. Fuel return hose2.

6. Vacuum pipe removal

1) Disconnect the leak-off hose from the leak-off pipe.

2) Disconnect the vacuum hose from the vacuum pipe.

3) Remove the harness bracket from the inlet manifold and common rail (fuel rail) bracket.

4) Remove the vacuum pipe from the inlet manifold.

7. Fuel leak-off pipe removal

1) Remove the fuel leak-off pipe from the fuel supply pump and common rail (fuel rail).

Caution


Legend

Fuel leak-off pipe1.

8. FRP sensor disconnect

1) Disconnect the connector from the FRP sensor.

9. Injection pipe removal

1) Remove the clip from the injection pipe.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution

Do not reuse the injection pipe.

10. Swirl control solenoid valve removal

1. Euro2 and Euro4 specifications

1) Disconnect the connector from the swirl control solenoid valve.

2) Disconnect the vacuum hose from swirl control solenoid valve.

3) Remove the swirl control solenoid valve from the common rail (fuel rail) bracket.

Legend

Swirl control solenoid valve1.

11. Common rail (fuel rail) removal

1) Remove the common rail (fuel rail) and bracket from the cylinder block.

Caution

Do not hold the FRP sensor.

Take care not to damage the connector section of the FRP sensor.

2) Remove the vacuum pipe from the cylinder block.

Legend

Vacuum pipe1. Common rail (fuel rail) bracket2. Common rail (fuel rail)3.

Common rail (fuel rail) installation (4JJ1 without DPD)

1. Component views


Part name


Tightening torque

1: 25 N・m 2.5 kgf・m / 18 lb・ft

4: 25 N・m 2.5 kgf・m / 18 lb・ft

2. Common rail (fuel rail) installation

1) Install the vacuum pipe to the cylinder block.

Tightening torque: 25 N・m 2.5 kgf・m / 18 lb・ft

2) Temporarily tighten the common rail (fuel rail) and bracket to the cylinder block.

Caution



Legend


3) Final tighten the common rail (fuel rail) and bracket to the cylinder block in the order shown in the diagram.


3. Swirl control solenoid valve installation


1) Install the swirl control solenoid valve to the common rail (fuel rail) bracket.


2) Connect the vacuum hose to swirl control solenoid valve.

3) Connect the connector to swirl control solenoid valve.

Legend


4. Injection pipe installation

1) Apply engine oil to the threaded portions of the sleeve nuts on the injector side, as well as the injector O-rings.

2) Temporarily tighten the injection pipes to the common rail (fuel rail) and injectors by hand until the sleeve nutscan no longer turn.

Caution


3) Temporarily tighten the clip to the injection pipe.

4) Final tighten the injector clamp tightening bolt to the cylinder head.


5) Final tighten the injection pipes to the injectors and common rail (fuel rail).

Tightening torque: 29.5 N・m 3.0 kgf・m / 22 lb・ft Injector side

Tightening torque: 29.5 N・m 3.0 kgf・m / 22 lb・ft Common rail (fuel rail) side

6) Securely tighten the clip to the injection pipe.


5. FRP sensor connect

1) Connect the connector to the FRP sensor.

6. Fuel leak-off pipe installation

1) Install the fuel leak-off pipe to the fuel supply pump and common rail (fuel rail).


Legend


7. Vacuum pipe installation

1) Install the vacuum pipe to the inlet manifold.


2) Install the harness bracket to the inlet manifold and common rail (fuel rail) bracket.


3) Connect the vacuum hose to the vacuum pipe.

4) Connect the leak-off hose to the leak-off pipe.

8. Fuel hose connect

1) Connect the fuel return hose to the fuel leak-off pipe.

2) Connect the fuel feed hose to the fuel supply pump.

Legend

Fuel return hose1. Fuel feed hose2.

9. Fuel feed pipe installation

1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).

Caution

Do not reuse the fuel feed pipe.

Tightening torque: 29.5 N・m 3.0 kgf・m / 22 lb・ft

Legend

Fuel feed pipe1.

10. Starter motor installation

Refer to "1.Engine 1J.Electrical(4JJ1 without DPD) starter motor installation".


1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the settings for the steering angle sensor and for the front door powerwindow switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

Filler neck removal (4JJ1 without DPD)





Caution






2. Fuel filler cap removal

1) Loosen the fuel filler cap gradually.

Caution

The fuel may burst out due to the pressure change in the fuel tank.

2) Remove the fuel filler cap from the filler neck.

Caution

Seal the filler neck to prevent foreign material from entering.

3. Rear mudguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors rear mudguard removal".

4. Filler neck removal

1) Place marks on the filler neck clamp, each fixing section, and band clip.

2) Remove the filler neck from the rear body and fuel filler hose.

Caution

Seal the hose and pipe to prevent foreign material from entering.

3) Disconnect the breather hose from the filler neck.

Caution


4) Disconnect the evaporator hose from the filler neck.

Caution


Legend

Fuel filler hose1. Evaporator hose2. Breather hose3.

Filler neck installation (4JJ1 without DPD)

1. Filler neck installation

1) Connect the evaporator hose to the filler neck.

Caution

Install to the original position by aligning the marks applied before removing.

2) Connect the breather hose to the filler neck.

Caution


3) Install the filler neck to the rear body and fuel filler hose.

Caution


Tightening torque: 6.0 N・m 0.6 kgf・m / 53 lb・in Screw

Tightening torque: 3.5 N・m 0.36 kgf・m / 31.0 lb・in Clamp

Legend


2. Rear mudguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors rear mudguard installation".

3. Fuel filler cap installation

1) Install the fuel filler cap to the filler neck.

Caution

Tighten it until it clicks at least 3 times.


1. Post procedures










Note


FRP regulator removal (4JJ1 without DPD)

1. Component views

FRP regulator

Part name

Fuel supply pump1. O-ring2. FRP regulator3. Bolt4.

Tightening torque

4: 9.0 N・m 0.9 kgf・m / 80 lb・in





Caution





3. Battery removal

1) Disconnect the battery ground cable from the frame.

2) Disconnect the battery cable from the battery.

3) Remove the battery bracket from the frame.

4) Remove the battery from vehicle.

Legend

Battery cable1. Battery bracket2. Battery ground cable3.

4. FRP regulator removal

1) Disconnect the connector from the FRP regulator.

Caution

Do not damage the connector by applying excessive force.

Legend

Fuel temperature sensor1. FRP regulator2.

2) Remove the FRP regulator from the fuel supply pump.

3) Remove the O-ring from the fuel supply pump.

Legend

O-ring1.

FRP regulator installation (4JJ1 without DPD)

1. Component views

FRP regulator

Part name


Tightening torque

4: 9.0 N・m 0.9 kgf・m / 80 lb・in

2. FRP regulator installation

1) Install the O-ring to the fuel supply pump.

Legend

O-ring1.

2) Temporarily tighten the FRP regulator by hand until it attaches securely to the fuel supply pump.

Caution

Do not allow the O-ring to get caught.

3) Final tighten the FRP regulator to the fuel supply pump.


4) Connect the connector to the FRP regulator.

3. Battery installation

1) Install the battery to vehicle.

2) Install the battery bracket to the frame.

Tightening torque: 4.0 N・m 0.4 kgf・m / 35 lb・in Battery side

Tightening torque: 20 N・m 2.0 kgf・m / 15 lb・ft Frame side

3) Connect the battery cable to the battery.

4) Connect the battery ground cable to the frame.

Legend



1. Post procedures






5. ECM setting

Note

If repairing or replacing the fuel supply pump, perform Fuel Supply Pump Relearning.

1. Fuel Supply Pump Relearning

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

DiagnosticsEngine4JJ1Actuator Test

Fuel Supply Pump Learn Resetting

4) Reset the Fuel Supply Pump Learning by following the on-screen instructions.

5) Turn OFF the ignition switch for 30 seconds.

6) Start and idle the engine until the engine coolant temperature reaches 65°C 149°F or more.

7) Observe the Fuel Supply Pump Learning Status parameter on the scan tool.

8) The procedure is complete when the parameter changes from Not Learned to Learned.

Fuel filler cap removal (4JJ1 without DPD)



Caution



Caution


Fuel filler cap inspection (4JJ1 without DPD)

1. Fuel filler cap inspection

1) Inspect the seal ring of the fuel filler cap.

Caution

Because replacing may cause an engine performance decrease, make sure to use the same type.

Legend

Seal ring1.

Fuel filler cap installation (4JJ1 without DPD)



Caution


Fuel filter element removal (4JJ1 without DPD)





Caution





2. Fuel filter element removal

1) Remove the element case and O-ring from the fuel filter body.

2) Remove the fuel filter element from the element case.

Caution

Do not reuse the O-ring.

Use an ISUZU genuine fuel filter for element replacement.

Legend

Fuel filter body1. Fuel filter element2. O-ring3. Element case4.

Fuel filter element installation (4JJ1 without DPD)

1. Fuel filter element installation

1) Install the fuel filter element to the element case.

2) Install the element case and O-ring to the fuel filter body.

Legend

Fuel filter body1. Fuel filter element2. O-ring3. Element case4.


1. Post procedures






3. Fuel air bleed


Caution


Legend


Fuel filter removal (4JJ1 without DPD)

1. Component views

Fuel filter

Part name

Pressure switch1. Priming pump2. Fuel feed hose (Fuel tank side)3. Fuel filter4. Fuel return hose5. Fuel feed hose (Supply pump side)6.





Caution





3. Fuel filter removal

1) Disconnect the connector from the fuel sedimenter switch.

2) Disconnect the connector from the pressure switch.

3) Remove the fuel filter from the fuel filter bracket.

4) Disconnect the fuel feed hose from the fuel filter.

Caution

Insert a plug so that fuel does not spill.

Fuel filter inspection (4JJ1 without DPD)

1. Fuel filter inspection

1) Inspect for continuity between the pressure switch terminals using a DMM.

Note

If there is continuity, replace the fuel filter.

2) Connect the vacuum pump to the engine side feed pipe of the fuel filter.

3) Seal the feed pipe on the fuel tank side using caps, cloth tape, etc.

Caution

Make sure to prevent fuel from entering the vacuum pump.

4) Apply a vacuum using a vacuum pump, and inspect for continuity when pressurizing to the standard value.

Standard: -38 to -42 kPa -0.39 to -0.43 kgf/cm2 / -5.5 to -6.1 psi

Note

If there is no continuity, replace the fuel filter.

Fuel filter installation (4JJ1 without DPD)

1. Component views

Fuel filter

Part name


2. Fuel filter installation

1) Connect the fuel feed hose to the fuel filter.

2) Install the fuel filter to the fuel filter bracket.

3) Connect the connector to the pressure switch.

4) Connect the connector to the fuel sedimenter switch.


1. Post procedures






4. Fuel air bleed



Caution


Legend


Fuel supply pump removal (4JJ1 without DPD)

1. Component views

Fuel supply pump

Part name

Supply pump gear nut1. Supply pump sprocket2. Supply pump gear3. Fuel supply pump4. Nut5.

Tightening torque

1: 130 N・m 13.3 kgf・m / 96 lb・ft

5: 25 N・m 2.5 kgf・m / 18 lb・ft





Caution






3. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

4. Coolant drain

Warning

Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result inburns caused by the release of steam or hot water.

When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooledand slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

Legend

Drain plug1.

4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.

5) Tighten the drain plug on the cylinder block.


6) Tighten the radiator drain plug.

5. Engine cover removal

1) Remove the engine cover from the engine.

Legend

Engine cover1.

6. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the connector from the barometric pressure sensor.

3) Disconnect the blow-by hose from the air cleaner.

4) Disconnect the vacuum hose from the air cleaner.

5) Disconnect the intake pipe from the turbocharger.

6) Remove the air cleaner from the vehicle.

Legend

Air cleaner1. MAF and IAT sensor2. Vacuum hose3. Blow-by hose4. Intake pipe5. Barometric pressure sensor6.

7. Intake air duct removal

1) Remove the intake hose and intake air duct as a set from the turbocharger and intercooler.

8. Boost pressure sensor disconnect

1) Disconnect the connector from the boost pressure sensor.

9. Intake air duct removal

1) Remove the intake hose and intake air duct as a set from the intake throttle valve and intercooler.

10. Radiator upper hose removal

1) Remove the radiator upper hose from the water outlet pipe and radiator.

Legend

Radiator upper hose1.

11. Battery removal

1) Disconnect the battery ground cable from the frame.

2) Disconnect the battery cable from the battery.

3) Remove the battery bracket from the frame.

4) Remove the battery from vehicle.

Legend


12. Radiator reserve tank removal

1) Disconnect the radiator reserve tank hose from the radiator.

2) Remove the radiator reserve tank from the fan guide.

13. Fan guide removal

1) Remove the fan shroud from the fan guide.

2) Remove the fan guide from the radiator.

Legend

Fan guide1. Clip2. Fan shroud3.

14. Cooling fan removal

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.

2) Remove the fan pulley from the water pump.

15. A/C compressor drive belt removal

1. Models with A/C compressor

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the A/C compressor drive belt from the following parts.

Tension pulleyA/C compressorCrankshaft pulley

Legend

Lock nut1. Adjust bolt2. A/C compressor drive belt3.

16. A/C compressor disconnect


1) Disconnect the A/C compressor from the A/C compressor bracket.

Legend

A/C compressor bracket1. A/C compressor2.

17. A/C compressor bracket removal


1) Remove the A/C compressor bracket from the cylinder head.

2. Models without A/C compressor

1) Remove the bracket from the A/C compressor bracket.

2) Remove the A/C compressor bracket from the cylinder head.

18. Water pipe removal

1) Remove the water pipe from the following parts.

Water outlet pipeCylinder headTurbocharger

Except Euro4 specifications

Euro4 specifications

19. Tension pulley removal

1) Remove the tension pulley from the cylinder head.

20. Exhaust manifold heat protector removal

1. Except Euro4 specifications

1) Remove the exhaust manifold heat protector from the exhaust manifold and bracket.

Without EGR


2. Euro4 specifications

1) Remove the exhaust manifold heat protector from the exhaust manifold and EGR cooler.

21. EGR pipe removal


1) Remove the EGR pipe and gasket from the inlet manifold and exhaust manifold.

22. Starter motor removal

Refer to "1.Engine 1J.Electrical(4JJ1 without DPD) starter motor removal".

23. Fuel leak-off hose removal

1) Disconnect the connector from the injector.

2) Remove the fuel leak-off hose from the leak-off pipe.

Caution

Do not reuse the clips.

Legend

Fuel leak-off hose1. Injector connector2.

3) Remove the injector leak-off pipe from the injector.

Caution

Do not reuse the injector leak-off pipe or clip.

Legend

Injector leak-off pipe1. Clip2.

24. Cylinder head cover removal

1) Disconnect the blow-by hose from the cylinder head cover.

2) Disconnect the harness clip from the cylinder head cover.

3) Remove the cylinder head cover from the cylinder head.

4) Remove the oil seal from the lower side of the cylinder head cover.

25. Fuel feed pipe removal

1) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).

Caution


Legend

Fuel feed pipe1.

26. Fuel hose disconnect

1) Disconnect the fuel feed hose from the fuel supply pump.

2) Disconnect the fuel return hose from the fuel leak-off pipe.

Legend

Fuel feed hose1. Fuel return hose2.



Caution


Legend


28. FRP sensor disconnect

1) Disconnect the connector from the FRP sensor.




Caution


30. Swirl control solenoid valve removal


1) Disconnect the connector from the swirl control solenoid valve.

2) Disconnect the vacuum hose from swirl control solenoid valve.

3) Remove the swirl control solenoid valve from the common rail (fuel rail) bracket.

Legend


31. Common rail (fuel rail) removal

1) Remove the common rail (fuel rail) and bracket from the cylinder block.

Caution



2) Remove the vacuum pipe from the cylinder block.

Legend


32. Timing chain lower cover removal

1) Remove the noise cover from the timing chain lower cover.

2) Remove the timing chain lower cover from the gear case cover.

33. Timing chain upper cover removal

1) Disconnect the connector from the CMP sensor.

Legend

CMP sensor1.

2) Remove the timing chain upper cover from the cylinder head.

Legend

Timing chain upper cover1.

34. Timing chain removal

1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression topdead center.

Note

Check the alignment position using a mirror, etc.

Legend

Top dead center alignment mark on the gear case cover side1. Top dead center alignment mark on the crank pulley side2.

2) Align the marks of the camshaft upper bracket and camshaft.

Legend

Alignment mark1.

3) Remove the oil feed pipe from the timing chain tensioner.

4) Remove the timing chain tensioner and gasket from the cylinder head.

Legend

Oil feed pipe1. Timing chain tensioner2. Gasket3.

5) Remove the timing chain lever pivot from the timing chain tension lever.

6) Remove the supply pump gear nut from the sprocket.

Legend

Supply pump gear nut1.

7) Remove the supply pump sprocket from the supply pump gear.

Legend

Timing chain lever pivot1. Supply pump sprocket2. Nut3.

8) Referring to the diagram, remove the timing chain from the supply pump sprocket.

35. Fuel supply pump removal

1) Mark the alignment positions of idle gear A and the supply pump gear.

2) Remove the supply pump gear from the fuel supply pump using a gear puller.

3) Disconnect the connector from the fuel temperature sensor.

4) Disconnect the connector from the FRP regulator.

Legend

Fuel temperature sensor connector1. FRP regulator connector2.

5) Remove the fuel supply pump from the timing gear case.

Caution

Do not hold the high pressure pipe.

Legend

Fuel supply pump1.

6) Remove the O-ring from the fuel supply pump.

Legend

Fuel supply pump1. O-ring2.

Fuel supply pump installation (4JJ1 without DPD)

1. Component views

Fuel supply pump

Part name


Tightening torque

1: 130 N・m 13.3 kgf・m / 96 lb・ft

5: 25 N・m 2.5 kgf・m / 18 lb・ft

2. Fuel supply pump installation

1) Apply soapy water to the O-ring.

2) Install the O-ring to the fuel supply pump.

Caution

Do not pinch the O-ring.

3) Install the fuel supply pump to the timing gear case.


Legend

Fuel supply pump1.

4) Confirm that the supply pump camshaft key is located in a horizontal position on the right side when seen fromthe front.

5) Install the supply pump gear to idle gear A by aligning the alignment marks.

Caution

Check that the supply pump gear and main gear of idle gear A are securely engaged.

Legend

Supply pump gear alignment mark1. Idle gear marking2. Main gear3. Sub-gear4.

6) Connect the connector to the FRP regulator.

7) Connect the connector to the fuel temperature sensor.

3. Timing chain installation

1) Align the idle gear D alignment mark with the blue link of the timing chain.

2) Install the timing chain to the supply pump sprocket.

3) Align the supply pump sprocket alignment mark with the yellow plate position of the timing chain.

Legend

Timing chain1. Timing mark2. Blue link3. Yellow link4.

4) Align the supply pump gear dowel pin with the notched section of the supply pump sprocket, and then installthe supply pump sprocket to the supply pump gear.


Legend

Nut1.

5) Install the timing chain lever pivot to the timing chain tension lever.


6) Push down the timing chain tensioner latch and insert the plunger.

Note

Install the hook to the pin while pressing the plunger.

Legend

Pin1. Plunger2. Latch3. Hook4.

7) Install the timing chain tensioner and gasket to the cylinder head.

Caution

Do not reuse the gasket.


8) Install the oil feed pipe to the timing chain tensioner.


Legend

Oil feed pipe1. Timing chain tensioner2. Gasket3.

9) Lightly press the area indicated by the arrow in the diagram to disconnect the hook from the pin.

Note

The hook of the tensioner opens and the plunger pushes the tension lever to pull the chain.

4. Timing chain upper cover installation

1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain upper cover.

Caution

Install the timing chain cover within 5 minutes of applying the liquid gasket.

Legend

Liquid gasket1.

Standard value

a: 1.0 to 1.5 mm 0.039 to 0.059 in Bead height

b: 2.0 to 2.5 mm 0.079 to 0.098 in Bead width

2) Install the timing chain upper cover to the cylinder head.

Caution

Wipe off any excess liquid gasket.


3) Connect the connector to the CMP sensor.

5. Timing chain lower cover installation

1) Referring to the diagram, apply ThreeBond 1207C or equivalent to the timing chain lower cover.

Caution

Install the timing chain cover within 5 minutes of applying the liquid gasket.

Legend

Liquid gasket1.

Standard value

a: 2.0 to 2.5 mm 0.079 to 0.098 in Bead height

b: 2.0 to 2.5 mm 0.079 to 0.098 in Bead width

2) Install the timing chain lower cover to the gear case cover.


3) Install the noise cover to the timing chain lower cover.


6. Common rail (fuel rail) installation

1) Install the vacuum pipe to the cylinder block.


2) Temporarily tighten the common rail (fuel rail) and bracket to the cylinder block.

Caution



Legend


3) Final tighten the common rail (fuel rail) and bracket to the cylinder block in the order shown in the diagram.


7. Swirl control solenoid valve installation


1) Install the swirl control solenoid valve to the common rail (fuel rail) bracket.


2) Connect the vacuum hose to swirl control solenoid valve.

3) Connect the connector to swirl control solenoid valve.

Legend





Caution










9. FRP sensor connect

1) Connect the connector to the FRP sensor.




Legend


11. Fuel hose connect

1) Connect the fuel return hose to the fuel leak-off pipe.

2) Connect the fuel feed hose to the fuel supply pump.

Legend

Fuel return hose1. Fuel feed hose2.

12. Fuel feed pipe installation

1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).

Caution

Do not reuse the fuel feed pipe.


Legend

Fuel feed pipe1.

13. Cylinder head cover installation

1) Apply the engine oil to the oil seal.

2) Insert the oil seal from the lower side of the cylinder head cover until it reaches the far end.

3) Referring to the diagram, apply ThreeBond 1217H or 1207C to the cylinder head mating surface.

Caution

Install the cylinder head cover within 5 minutes of applying liquid gasket.

Remove any dirt or dust from the oil seal section on the injector connector side.

Legend

Liquid gasket1.

Standard value

a: 2.0 to 2.5 mm 0.079 to 0.098 in Bead width

b: 1.0 to 1.5 mm 0.039 to 0.059 in Bead height

4) Temporarily tighten the cylinder head cover to the cylinder head in the order shown in the diagram.

Caution



5) Final tighten the cylinder head cover to the cylinder head in the order shown in the diagram.


6) Connect the harness clip to the cylinder head cover.

7) Connect the blow-by hose to the cylinder head cover.

14. Fuel leak-off hose installation

1) Install the injector leak-off pipe to the injector.

Legend

Injector leak-off pipe1. Clip2.

2) Install the fuel leak-off hose to the leak-off pipe.

3) Connect the connector to the injector.

Legend

Fuel leak-off hose1. Injector connector2.

15. Starter motor installation

Refer to "1.Engine 1J.Electrical(4JJ1 without DPD) starter motor installation".

16. EGR pipe installation


1) Install the EGR pipe and gasket to the inlet manifold and exhaust manifold.


Caution


17. Exhaust manifold heat protector installation

1. Except Euro4 specifications

1) Install the exhaust manifold heat protector to the exhaust manifold and bracket.


Without EGR



1) Install the exhaust manifold heat protector to the exhaust manifold and EGR cooler.


18. Tension pulley installation


1) Install the tension pulley to the cylinder head.


19. Water pipe installation

1) Install the water pipe to the following parts.

Water outlet pipeCylinder headTurbocharger

Tightening torque: 10.0 N・m 1.0 kgf・m / 89 lb・in Bolt, nut

Except Euro4 specifications


20. A/C compressor bracket installation


1) Temporarily tighten the A/C compressor bracket to the cylinder head.

2) Final tighten the A/C compressor bracket to the cylinder head in the order shown in the diagram.


2. Models without A/C compressor

1) Temporarily tighten the A/C compressor bracket to the cylinder head.

2) Final tighten the A/C compressor bracket to the cylinder head in the order shown in the diagram.


3) Install the bracket to the A/C compressor bracket.


21. A/C compressor connect


1) Connect the A/C compressor to the A/C compressor bracket.


Legend

A/C compressor bracket1. A/C compressor2.

22. Oil level gauge guide tube installation

1) Apply engine oil to the O-ring.

2) Install the oil level gauge guide tube to the crankcase and inlet manifold.


3) Install the oil level gauge to the oil level gauge guide tube.

23. A/C compressor drive belt installation


1) Install the A/C compressor drive belt to the following parts.

Tension pulleyA/C compressorCrankshaft pulley

Legend

Lock nut1. Adjust bolt2. A/C compressor drive belt3.

24. Cooling fan installation

1) Install the fan pulley to the water pump.

2) Install the cooling fan and cooling fan clutch as a set to the water pump.


25. Fan guide installation

1) Install the fan guide to the radiator.


2) Install the fan shroud to the fan guide.

Legend

Fan guide1. Clip2. Fan shroud3.

26. Radiator reserve tank installation

1) Clean the radiator reserve tank using detergent.

Note

Wash with clean water, and drain the water.

2) Install the radiator reserve tank to the fan guide.


3) Connect the radiator reserve tank hose to the radiator.

27. Battery installation

1) Install the battery to vehicle.

2) Install the battery bracket to the frame.

Tightening torque: 4.0 N・m 0.4 kgf・m / 35 lb・in Battery side

Tightening torque: 20 N・m 2.0 kgf・m / 15 lb・ft Frame side

3) Connect the battery cable to the battery.

4) Connect the battery ground cable to the frame.

Legend


28. Radiator upper hose installation

1) Install the radiator upper hose to the water outlet pipe and radiator.

Legend

Radiator upper hose1.

29. Intake air duct installation

1) Install the intake hose and intake air duct as a set to the intake throttle valve and intercooler.

Caution

Align the marks on the pipe side and hose side.

Tightening torque: 10.0 N・m 1.0 kgf・m / 89 lb・in Bolt

Tightening torque: 4.0 N・m 0.4 kgf・m / 35 lb・in Clamp (Intake throttle side)

Tightening torque: 5.0 N・m 0.5 kgf・m / 44 lb・in Clamp (Intercooler side)

30. Boost pressure sensor connect

1) Connect the connector to the boost pressure sensor.

31. Intake air duct installation

1) Install the intake hose and intake air duct as a set to the turbocharger and intercooler.

Caution

Referring to the diagram, face the threaded portion of the clamp toward the engine front.

Tightening torque: 25 N・m 2.5 kgf・m / 18 lb・ft Nut, bolt

Tightening torque: 4.0 N・m 0.4 kgf・m / 35 lb・in Clamp (Turbocharger side)

Tightening torque: 5.0 N・m 0.5 kgf・m / 44 lb・in Clamp (Intercooler side)

32. Engine cover installation

1) Install the engine cover to the engine.

Legend

Engine cover1.

33. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".


1. Post procedures







35. Fuel air bleed



Caution


Legend


36. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note

Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution

Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiatorwith engine coolant.

Note

Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolantlowers.

Caution

Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

Legend

Radiator reserve tank1. MAX line2. MIN line3.

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution

Idle the engine for 5 minutes or more.

6) Stop the engine.


Warning




Note

If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.



11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant

temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note

Touch the radiator upper hose, and confirm that it has become warm.

If it has not become warm, go back to Step 11.

Caution

Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.


Warning




Note

Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.


19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution

If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.

37. A/C compressor drive belt adjustment


When installing a new belt, initial stretching of the belt occurs.In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.After fitting the A/C compressor drive belt, adjust the tension of the A/C compressor drive belt again.

1) Loosen the tension pulley lock nut.

2) Turn the tension pulley adjust bolt to adjust the tension.

Note

The standard deflection shown is the value obtained when the specified load is applied to themeasurement point of the A/C compressor drive belt.

98 N 10.0 kg / 22 lb Load

Caution

Accurately adjust the tension as there is a possibility the service life of the belt may be shortened orbelt squeal may be generated if the tension is not within the appropriate range.

Use a sonic tension meter to verify accurate tension adjustment.

Measurement point 1Adjustmentconditions

DeflectionVibrationfrequency

When new12.5 to 16.5mm 0.49 to

0.65 in

92 to 112Hz

Reused16.5 to 19.1mm 0.65 to

0.75 in

79 to 91Hz




0.81 in

70 to 86Hz


0.93 in

62 to 70Hz




0.65 in

92 to 112Hz


0.75 in

80 to 92Hz

Legend

A/C compressor drive belt1. Tension pulley lock nut2. Tension pulley adjust bolt3.

Measurement point 14. Measurement point 25. Measurement point 36.

3) Tighten the tension pulley lock nut to the specified torque.


38. ECM setting

Note

If repairing or replacing the fuel supply pump, perform Fuel Supply Pump Relearning.

1. Fuel Supply Pump Relearning




DiagnosticsEngine4JJ1Actuator TestFuel Supply Pump Learn Resetting

4) Reset the Fuel Supply Pump Learning by following the on-screen instructions.

5) Turn OFF the ignition switch for 30 seconds.

6) Start and idle the engine until the engine coolant temperature reaches 65°C 149°F or more.

7) Observe the Fuel Supply Pump Learning Status parameter on the scan tool.

8) The procedure is complete when the parameter changes from Not Learned to Learned.

Fuel tank removal (4JJ1 without DPD)

1. Component views

Fuel tank

Part name

Fuel feed tube1. Fuel tank2. Fuel filler hose3. Breather hose4. Evaporator hose5. Bolt6. Fuel tank band7. Fuel return tube8. Fuel tank protector9.

Tightening torque

6: 68 N・m 6.9 kgf・m / 50 lb・ft



Caution



Caution


3. Fuel tube disconnect

1) Disconnect the fuel feed hose from the fuel feed tube.

Caution

Plug to prevent fuel from coming out, then face it upward and tie it to the frame side.

2) Disconnect the fuel return hose from the fuel return tube.

Caution

Plug to prevent fuel from coming out, then face it upward and tie it to the frame side.

Legend

Fuel feed tube1. Fuel return tube2.

4. Fuel tank removal

1) Disconnect the fuel filler hose from the filler neck.

Caution


2) Disconnect the breather hose from the filler neck.

Caution


3) Disconnect the evaporator hose from the filler neck.

Caution


Legend


4) Support the lower section of the fuel tank using the lifter.

5) Remove the fuel tank band from the frame.

6) Disconnect the connector from the fuel tank unit.

7) Remove the fuel tank from vehicle.

8) Lower the lifter and remove the fuel tank from the vehicle.

Caution

Do not let the fuel hose and fuel tube interfere with other components.

Fuel tank installation (4JJ1 without DPD)

1. Component views

Fuel tank

Part name


Tightening torque

6: 68 N・m 6.9 kgf・m / 50 lb・ft

2. Fuel tank installation

1) Support the fuel tank using the lifter.

2) Install the fuel tank to the vehicle by raising the lifter.

Caution

Do not let the fuel hose and tube interfere with other components.

3) Connect the connector to the fuel tank unit.

Caution

Securely connect the connector to the stopper.

4) Install the fuel tank band to the frame.


Caution

Securely install the tank band anchor to the guide hole of the frame.

5) Connect the evaporator hose to the filler neck.

6) Connect the breather hose to the filler neck.

7) Connect the fuel filler hose to the filler neck.

Tightening torque: 3.5 N・m 0.36 kgf・m / 31.0 lb・in Clamp

Legend


8) Remove the lifter from the fuel tank.

3. Fuel tube connect

1) Connect the fuel return hose to the fuel return tube.

2) Connect the fuel feed hose to the fuel feed tube.

Legend

Fuel return tube1. Fuel feed tube2.



Caution


5. Fuel air bleed



Caution


Legend





Note


Fuel tank unit removal (4JJ1 without DPD)

1. Component views

Fuel tank unit

Part name

Retainer ring1. Fuel tank unit2. Fuel tank unit seal3. Fuel tank4.

Tightening torque

1: 125 N・m 12.7 kgf・m / 92 lb・ft

2. Fuel tube removal

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) fuel tube removal".

3. Fuel tank unit removal

1) Remove the retainer ring from the fuel tank using the special tool.

Caution

Do not reuse the retainer ring.

Cover the retainer ring with a shop cloth, etc.

Breakage may occur if the special tool comes into contact with the ribbed bottom portion of theretainer ring.

SST: 5-8840-2990-0 - Wrench;Chain

2) Remove the fuel tank unit from the fuel tank.

Caution

The fuel tank unit seal cannot be reused.

Remove it gradually not to distort the float arm.

Cover the fuel tank to prevent foreign material from entering.

Fuel tank unit inspection (4JJ1 without DPD)

1. Fuel tank unit inspection

1. Airtight inspection

1) Connect the fuel filler hose to the filler neck and fuel tank.

2) Connect the breather hose to the filler neck and fuel tank.

3) Plug the return pipe connection outlet of the fuel tank unit.


Caution

Tighten until it makes a clicking sound at least once.

5) Apply soapy water to the area around the fuel tank unit seal.

6) Apply air from the feed side pipe of the fuel tank unit to the fuel tank for 15 seconds or more to the specifiedpressure.

34.3 kPa 0.3 kgf/cm2 / 5 psi Specified pressure

7) Verify that bubbles are not coming out around the fuel tank unit seal.

2. Resistance measurement

The fuel tank unit changes the internal resistance in accordance with the float position, which varies depending onthe fluid surface height, and operates the fuel meter indicator.

1) Move the float to each position and measure the resistance between the connector terminals using a DMM.

Legend

Positive side power supply terminal1. Ground terminal2.

Legend

a. Distance from bottom to E position

b. Distance from bottom to 1/4 position

c. Distance from bottom to 1/2 position

d. Distance from bottom to 3/4 position

e. Distance from bottom to F position

f. F position

g. 3/4 position

h. 1/2 position

i. 1/4 position

j. E position

Floatposition

DistanceNet

volumeResistance

Fposition

185.7mm

7.311 in

62.3 L 16.46US gal/ 13.70Imp.gal

14 to 20 Ω

3/4position

148.5mm

5.846 in

47.0 L 12.42US gal/ 10.34Imp.gal

31.25 to37.25 Ω

1/2position

116.6mm

4.591 in

32.8 L 8.66US gal/ 7.22

Imp.gal

42 to 48 Ω

1/4position

85.9 mm 3.382

in

19.4 L 5.12US gal/ 4.27

Imp.gal

69.75 to77.75 Ω

Eposition

33.3 mm 1.311

in

5.4 L 1.43

US gal/ 1.19

Imp.gal

140 Ω ormore

2) Connect the connector on the vehicle to the fuel tank unit and move the float.

3) Verify that the low fuel warning light illuminates when the float is at the E position.

Note

Replace the fuel tank unit if a malfunction is found.

Fuel tank unit installation (4JJ1 without DPD)

1. Component views

Fuel tank unit

Part name


Tightening torque

1: 125 N・m 12.7 kgf・m / 92 lb・ft

2. Fuel tank unit installation

1) Clean the seal surfaces of the fuel tank and fuel tank unit.

Caution

Keep the seal surface clean as foreign material on it causes fuel leakage.

2) Install the fuel tank unit seal to the fuel tank.

Note

Install along the groove of the fuel tank opening.

Caution

The fuel tank unit seal cannot be reused.

3) Align the fuel tank unit protrusions with the fuel tank depressions, and install the fuel tank unit to the fuel tank.

Caution

Install it gradually not to distort the float arm.

4) Install the retainer ring to the fuel tank using the special tool.

Caution

Do not reuse the retainer ring.

Cover the retainer ring with a shop cloth, etc.

Breakage may occur if the special tool comes into contact with the ribbed bottom portion of theretainer ring.

SST: 5-8840-2990-0 - Wrench;Chain


Legend

Ribbed bottom portion1.

5) Referring to the diagram, align the retainer ring alignment mark with the fuel tank side alignment mark.

Legend

Alignment mark on the fuel tank side1. Alignment mark on the retainer side2.

3. Fuel tube installation

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) fuel tube installation".

Fuel tube removal (4JJ1 without DPD)

1. Fuel tank removal

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) fuel tank removal".

2. Fuel tube removal

1) Clean off any dirt adhered to the quick connector fitting of the fuel tube using air.

2) Remove the fuel tube from the fuel tank unit.

Note

Hold the connector with one hand while pushing the release button of the quick connector and pullout the connector with the other hand.

Legend

Release button1.

Caution

Do not use any tool.

The connector connection should be removed with bare hands.

Push and pull the connector using lubricating oil until the pipe connection is disconnected.

Caution

Cover the removed connector with a plastic bag to prevent foreign material or water from entering.

Fuel tube inspection (4JJ1 without DPD)

1. Fuel tube inspection

1) Inspect the fuel tube for the following.

DamageDentCracking

Note

Replace the fuel tube if a malfunction is found.

Fuel tube installation (4JJ1 without DPD)

1. Fuel tube installation

1) Install the fuel tube to the fuel tank unit.

Note

Applying engine oil or diesel oil to the pipe makes port installation easy.

Caution

Insert the connector straight in until it clicks.

Pull it out with the standard force and make sure that it is securely locked.

Standard: 49 N 5.0 kg / 11 lb

2. Fuel tank installation

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) fuel tank installation".

Injector removal (4JJ1 without DPD)

1. Component views

Injector

Part name

Injector1. Injector clamp2. Injector clamp bolt3. Injector leak-off hose4. Pin5. Injection pipe6. Common rail (fuel rail)7. Sleeve nut8. Clip9.

Fuel supply pump10.

Tightening torque

3: 26 N・m 2.7 kgf・m / 19 lb・ft

6: 29.5 N・m 3.0 kgf・m / 22 lb・ft

8: 29.5 N・m 3.0 kgf・m / 22 lb・ft

9: 10.0 N・m 1.0 kgf・m / 89 lb・in

2. Cylinder head cover removal

Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) cylinder head cover removal".

3. Vacuum pipe removal

1) Disconnect the leak-off hose from the leak-off pipe.

2) Disconnect the vacuum hose from the vacuum pipe.

3) Remove the harness bracket from the inlet manifold and common rail (fuel rail) bracket.

4) Remove the vacuum pipe from the inlet manifold.




Caution


5. Injector removal

1) Remove the injector clamp from the injector.

2) Remove the injector from the cylinder head.

Note

If it is difficult to remove the injector, use a remover.

Store the removed injectors with the cylinder numbers attached.

Caution

Cover the exposed portion to prevent foreign material from getting into the fuel system.

Do not damage the injector nozzle.

Absolutely never touch the injector solenoids because that can hinder their performance or causedamage.

3) Remove the gasket from the injector.

4) Remove the O-ring from the injector.

Caution

Do not reuse the following parts.

ClipO-ringGasket

Legend

Injector1. Leak-off pipe2. Clip3. O-ring4. Gasket5.

Injector installation (4JJ1 without DPD)

1. Component views

Injector

Part name

Injector1. Injector clamp2. Injector clamp bolt3. Injector leak-off hose4. Pin5. Injection pipe6. Common rail (fuel rail)7. Sleeve nut8. Clip9.

Fuel supply pump10.

Tightening torque

3: 26 N・m 2.7 kgf・m / 19 lb・ft

6: 29.5 N・m 3.0 kgf・m / 22 lb・ft

8: 29.5 N・m 3.0 kgf・m / 22 lb・ft

9: 10.0 N・m 1.0 kgf・m / 89 lb・in

2. Injector installation

1) Apply engine oil to the O-ring.

2) Install the O-ring to the injector.

Caution

Do not damage the O-ring.

3) Clean the cylinder head installation surface and injector.

4) Drop the gasket into the port on the cylinder head side.

Caution

Check that the gasket is seated horizontally.

5) Check that the gasket has been inserted based on the nozzle height using the injector.

Caution

Do not reuse the leak-off pipe or clip.

Press the injector in perpendicularly to ensure that the gasket is not slanted.

Do not hold the injector connector.

Do not forcibly push the gasket into the injector as it will be pushed until it hits the end of the injectorduring clamp tightening.

Legend

Injector1. Leak-off pipe2. Clip3. O-ring4. Gasket5.

6) Install the injector clamp to the injector.

Legend

Injector1. Bolt2. Injector clamp3.

7) Apply engine oil to the threaded portions and seating surfaces of the bolts.

8) Install the injector and injector clamp to the cylinder head.

9) Temporarily tighten the injector clamp tightening bolt to the cylinder head.

1. When replacing the injector

Erase the old cylinder number ID code on the Injector ID Code label attached to the cylinder head cover with ablack pen, etc.

Label on the cylinder head cover (Sample)

Legend

No. 1 cylinder Injector ID Code1. No. 2 cylinder Injector ID Code2. No. 3 cylinder Injector ID Code3. No. 4 cylinder Injector ID Code4. Injector ID Code label5.

1) Record the Injector ID Code of the new injector.

Note

Record the 24 characters of the injector ID plate.

The correct order of the ID codes shown in the following injector illustration is as follows.72 04 F9 F8 F0 00 F0 E7 09 F6 F9 96

Injector (Sample)

Legend

Injector ID Code1. Injector2.




Caution










4. Vacuum pipe installation

1) Install the vacuum pipe to the inlet manifold.


2) Install the harness bracket to the inlet manifold and common rail (fuel rail) bracket.


3) Connect the vacuum hose to the vacuum pipe.

4) Connect the leak-off hose to the leak-off pipe.

5. Cylinder head cover installation

Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) cylinder head cover installation".

6. ECM setting

1. Injector ID Code programming

Note

If the injector is replaced, perform the Injector ID Code programming.




DiagnosticsEngine4JJ1ProgrammingInjector ID CodeProgram Injector ID Code

4) Program the Injector ID Code into the ECM by following the on-screen instructions.

5) After the programming is completed, turn the ignition switch OFF for 30 seconds.

Pre-fuel filter element removal (4JJ1 without DPD)

1. Pre-fuel filter element removal

1. Models with pre-fuel filter

When replacing the pre-fuel filter element, replace the fuel filter element at the same time.

Caution

Use an ISUZU genuine fuel filter for element replacement.

1) Remove the element case from the pre-fuel filter using the special tool.

SST: 5-8840-2992-0 - fuel filter wrench

Legend

5-8840-2992-01. Close2. Open3.

2) Remove the pre-fuel filter element from the element case.

Legend

Pre-fuel filter element1. Element case2.

Pre-fuel filter element installation (4JJ1 without DPD)

1. Pre-fuel filter element installation


1) Install the pre-fuel filter element to the element case.

Caution

After installing, securely insert the O-ring into the pre-fuel filter groove.

If the O-ring is misaligned with the groove of the pre-fuel filter, foreign material may enter the fuelsystem and the engine may be damaged.

2) Install the element case to the pre-fuel filter using the special tool.

SST: 5-8840-2992-0 - fuel filter wrench

Legend

5-8840-2992-01. Close2. Open3.

3) Referring to the diagram, align the union side alignment mark and element case side alignment mark positions.

Legend

Union side alignment mark1. Element case side alignment mark2.

2. Fuel air bleed



Caution


Legend


Pre-fuel filter removal (4JJ1 without DPD)

1. Pre-fuel filter removal


1) Disconnect the fuel hose from the pre-fuel filter.

Caution

Insert a plug so that fuel does not spill.

2) Remove the pre-fuel filter from the pre-fuel filter bracket.

2WD models

4WD models

Pre-fuel filter installation (4JJ1 without DPD)

1. Pre-fuel filter installation


1) Install the pre-fuel filter to the pre-fuel filter bracket.


2WD models

4WD models

2. Fuel air bleed



Caution


Legend


Pressure limiter removal (4JJ1 without DPD)

1. Component views

Pressure limiter

Part name

Common rail (fuel rail)1. FRP sensor2. Pressure limiter3.

Tightening torque

2: 98 N・m 10.0 kgf・m / 72 lb・ft

3: 172 N・m 17.5 kgf・m / 127 lb・ft





Caution







Caution


Legend


4. Pressure limiter removal

1) Remove the pressure limiter from the common rail (fuel rail).

Legend


Pressure limiter installation (4JJ1 without DPD)

1. Component views

Pressure limiter

Part name


Tightening torque

2: 98 N・m 10.0 kgf・m / 72 lb・ft

3: 172 N・m 17.5 kgf・m / 127 lb・ft

2. Pressure limiter installation

1) Install the pressure limiter to the common rail (fuel rail).


Legend





Legend



1. Post procedures






Water sedimenter switch removal (4JJ1 without DPD)

1. Fuel filter removal

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) fuel filter removal".

2. Water sedimenter switch removal

1) Remove the element case from the fuel filter body.

Caution


Legend

Element case1.

Water sedimenter switch inspection (4JJ1 without DPD)

1. Water sedimenter switch inspection

1. Operation inspection

1) Connect the connector to the water sedimenter switch.


3) Turn the element case upside down, and move the float.

4) Check whether the warning light in the instrument panel cluster illuminates.

Caution

If the warning light does not illuminate, inspect the continuity of the water sedimenter switch.

2. Continuity inspection

1) Turn the element case upside down, and move the float.

2) Make sure there is continuity between the terminals of the water sedimenter switch connector using a DMM.

3) Disconnect the connector from the water sedimenter switch.

4) Verify that the warning light on the sedimenter illuminates when connected between the connector terminals onthe vehicle side.

Note

At this time, the circuit is normal if the sedimenter warning light lights up.

If a malfunction is found, replace the water sedimenter switch or repair poor connections or opencircuits between the circuits.

Legend

Water sedimenter switch1. Vehicle side connector2. Harness3. Drain valve4.

Water sedimenter switch installation (4JJ1 without DPD)

1. Water sedimenter switch installation

1) Install the element case to the fuel filter body.

Caution


Legend

Element case1.

2. Fuel filter installation

Refer to "1.Engine 1C.Fuel System(4JJ1 without DPD) fuel filter installation".

Supplementary Information (4JJ1 without DPD)

1. Component views

Fuel filter

Part name


Injector

Part name

Injector1. Injector clamp2. Injector clamp bolt3. Injector leak-off hose4. Pin5. Injection pipe6. Common rail (fuel rail)7. Sleeve nut8. Clip9. Fuel supply pump10.

Tightening torque

3: 26 N・m 2.7 kgf・m / 19 lb・ft

6: 29.5 N・m 3.0 kgf・m / 22 lb・ft

8: 29.5 N・m 3.0 kgf・m / 22 lb・ft

9: 10.0 N・m 1.0 kgf・m / 89 lb・in


Part name


Tightening torque

1: 25 N・m 2.5 kgf・m / 18 lb・ft

4: 25 N・m 2.5 kgf・m / 18 lb・ft

Pressure limiter

Part name


Tightening torque

2: 98 N・m 10.0 kgf・m / 72 lb・ft

3: 172 N・m 17.5 kgf・m / 127 lb・ft

Fuel supply pump

Part name


Tightening torque

1: 130 N・m 13.3 kgf・m / 96 lb・ft

5: 25 N・m 2.5 kgf・m / 18 lb・ft

FRP regulator

Part name


Tightening torque

4: 9.0 N・m 0.9 kgf・m / 80 lb・in

Fuel tank

Part name


Tightening torque

6: 68 N・m 6.9 kgf・m / 50 lb・ft

Fuel tank unit

Part name


Tightening torque

1: 125 N・m 12.7 kgf・m / 92 lb・ft

Fuel inspection (4JJ1 without DPD) - CITEC

Documents