fuel ISUZU TF SERIES 2004 Manual Online

FUEL SYSTEM 6C – 23



4JA1T (L)
RTW46CSH000101





4JA1TC/4JH1TC
RTW36AMH000101


















2. Injection Pump Bracket
1) Install the injection pump bracket (6) and the bracket
bolts (7) and (8) to the cylinder body. Temporarily
tighten the bracket bolts.
2) Tighten the bracket bolts (7) to the specified torque.
3) Tighten the bracket bolts (8) to the specified torque.
Note:
Tighten the bracket bolt (8) first.
Injection Pump Bracket Torque N·m(kg·m / lb ft)
(8) 19 (1.9 / 14)

(7) 40 (4.1 / 30)









3. Timing Check Hole Cover
Install the timing check hole cover and tighten bolts to the
specified torque.
Timing Check Hole Cover Bolts
Torque N·m(kg·m / lb ft)
8 (0.8 / 69)















4. Injection Pump Cover (4JA1TC/4JH1TC only)
5. Intake Manifold
1) Install the intake manifold with gasket.
Intake Manifold Bolts
Torque N·m(kg·m / lb ft)
19 (1.9 / 14)

Intake Manifold Nuts Torque N·m(kg·m / lb ft)
24 (2.4 / 17)

2) Install the EGR valve to the intake manifold and EGR
pipe temporarily.
3) Tighten the nuts and bolts to the specified torque

Torque N
m (kg
m/lb ft)
Nuts 24 (2.4/17)
Bolts 27 (2.8/20)

6C – 24 FUEL SYSTEM




6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque N·m(kg·m / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
40 (4.1 / 30)





7. Injection Pipe Clip
Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.

Injection Pipe Clip Torque N·m(kg·m / lb in)
8 (0.8 / 69)

8. Leak Off Pipe and Leak Off Hose
Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.






9. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque N·m(kg·m / lb ft)
21 (2.1 / 15)









10. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly to bracket and tighten bolts
to the specified torque.
Fuel Filter Assembly Bolts
Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
11. Fuel Pipe
1) Connect the fuel hoses to the fuel filter or priming
pump.
2) Connect the fuel hoses to the injection pump.









12. Oil Level Gauge
Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque N·m(kg·m / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)

FUEL SYSTEM 6C – 25







13. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket

15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.


Euro under Euro I Euro II Euro III
4JA1L without with with Not used
4JA1TC Not used Not used Not used With cooler
(EGR cooler)
4JH1TC without with with With
(EGR cooler)

17. Accelerator Control Cable
1) Connect the accelerator cable to the injection pump
(4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery

6C – 26 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)
DISASSEMBLY




















080L200009


Disassembly Steps
1.
Retaining nut 9.
Collar
2.
Nozzle & pin 10.
Spring seat
3.
Spacer & pin 11.
First spring
4.
Lift Piece 12.
Shim (First nozzle opening
pressure adjustment)
5.
Spring seat 13.
Nozzle holder body
6.
Push rod 14.
Eye bolt
7.
Shim (Second nozzle opening
pressure adjustment) 15.
Gasket
8.
Second spring



Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.

FUEL SYSTEM 6C – 27
REASSEMBLY




















080L200010


Reassembly Steps
1.
Nozzle holder body 9.
Spring seat
2.
Shim (First opening pressure
adjustment) 10.
Lift Piece
3.
First spring 11.
Spacer & pin
4.
Spring seat 12.
Nozzle & pin
5.
Collar 13.
Retaining nut
6.
Second spring 14.
Gasket
7.
Push rod 15.
Eye bolt
8.
Shim (Second opening pressure
adjustment)











Important Operations
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.

6C – 28 FUEL SYSTEM

REASSEMBLY AND ADJUSTMENT PROCEDURE
1
First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.

2
Full needle valve lift confirmation Confirm the full needle valve lift in accordance with the
closed method.

3
Pre-lift confirmation

Confirm pre-lift in accordance with the closed method.

CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.

4
Second nozzle opening pressure
confirmation Confirm the second nozzle opening pressure in accordance
with the closed method.

5
Second nozzle opening pressure
adjustment Adjust the second nozzle opening pressure using the shim.

6
Final inspection Confirm the condition of the fuel spray with the nozzle and
nozzle holder assembled.







First nozzle opening pressure adjustment
Nozzle needle valve full-lift 0.25 mm (0.0098 in)
Nozzle needle valve pre-lift 0.04 mm(0.0016 in) at 20,000 kpa (2901 psi, 204 kg/cm2)
Nozzle pressure
4JA1T(L) 1st Stage 19.1 Mpa (2759 psi, 194 kg/cm2)
2nd Stage 25.5-27.0 Mpa (3768-3911 psi, 260-275 kg/cm2)

NOTE: Only 4JA1L can perform adjustment of a nozzle.

FUEL SYSTEM 6C – 29


Injection Nozzle Adjustment
First nozzle opening pressure adjustment
1.Clamp the nozzle holder in a vise.



2. Install the shim, first spring and spring seat in the
nozzle holder.



3. Install the collar, second spring, shim, spring seat and
pushrod in the nozzle holder.



4. Install the pins, lift piece and spacer in the nozzle
holder.



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6C – 30 FUEL SYSTEM

5. Install the pins in the spacer.
6. Install the nozzle on the spacer.



7. Hand-tighten the adjustment retaining nut together
with the gasket to the nozzle holder.
Retaining nut: 157892-3200 (Bosch AS)
Gasket: 157892-5100 (Bosch AS)
(Bosch AS = Bosch Automotive Systems Corporation)



8. Tighten the adjustment retaining nut to the specified
torque.
Torque: 5.1 kg·m (36.9 Ib·ft/50 N·m)




9. Set the nozzle holder to the nozzle tester.
10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.

CAUTION:
 Use a micrometer to measure shim thickness.

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FUEL SYSTEM 6C – 31
 First nozzle opening pressure adjusting shims
Parts No. (ISUZU) Thickness (mm)
115349-0420 0.40
115349-0430 0.50
115349-0440 0.52
115349-0450 0.54
115349-0460 0.56
115349-0470 0.58
115349-0480 0.60


115349-0490 0.70


Full needle valve lift confirmation
1. Install the gasket and plug on the adjustment retaining
nut.
Gasket: 026508-1140 (Bosch AS)
894227-6020 (ISUZU)
Plug: 157892-1600 (Bosch AS)



2. Position the nozzle holder with the nozzle facing down
and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 157892-5000 (Bosch AS)



3. Install the nut on the dial gauge holder.
Nut: 157892-1000 (Bosch AS)


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6C – 32 FUEL SYSTEM

4. Install the pin to the dial gauge.
Note:
The lengths of the pins do not include the
threaded portions.

Pin (L=100 mm): 157892-5200 (Bosch AS)
Dial gauge: 157954-3800 (Bosch AS)
185317-0150 (ISUZU)



5. Secure the dial gauge to the nozzle holder using the
nut so that the pin contacts the tip of the first spring
seat.

CAUTION:
 Secure the dial gauge so that a stroke of 2 mm can
be measured.

 Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)




6. Set the nozzle holder to the nozzle tester and put
needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.



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