Engine Izusu 4h Shop Manual

FUEL SY SYSTEM

6C-1

ENGINE 4H SERIES SECTION 6C

FUEL SYSTEM Contents GENERAL DESCRIPTION DESCRIPTION .............. ..................... ............. ............. ........6C-2 .6C-2 Fuel Flow ........................................................... 6C-3 Brief Explanation of Emission and Electrical Control System...............................................................6C-5 Governor (Model RLD-M) .................................. 6C-6 Injection Nozzle ................................................. 6C-7 Fuel Filter and Water Separator ........................ 6C-8 FUEL FILTER ASSEMBLY (Except 4HF1-2 model) .....6C-9 Component ........................................................ 6C-9 Removal ............................................................ 6C-9 Installation ......................................................... 6C-9 Cartridge Replacement....................................6C-10 FUEL FILTER ASSEMBLY (4HF1-2 model only) ...6C-12 Component ...................................................... 6C-12 Removal .......................................................... 6C-12 Installation ....................................................... 6C-12 Cartridge Replacement....................................6C-12 INJECTION NOZZLE ASSEMBLY......................6C-14 Component ...................................................... 6C-14 Removal .......................................................... 6C-15 Disassembly .................................................... 6C-17 Reassembly.....................................................6C-18 Disassembly .................................................... 6C-20 Reassembly and Opening Pressure Adjustment ....6C-21 Installation ....................................................... 6C-30 INJECTION PUMP ASSEMBLY (Except 4HF1-2 model) .....6C-33 Component ...................................................... 6C-33 Removal .......................................................... 6C-33 Installation ....................................................... 6C-36 INJECTION PUMP ASSEMBLY (4HF1-2 model only) ....6C-40 Component ...................................................... 6C-40 Installation ....................................................... 6C-40 INJECTION INJECTION TIMING ADJUSTMENT .............. ..................6C-45 ....6C-45 Injection Pump Notched Line Inspection .........6C-45 Injection Timing Adjustment (Except 4HF1-2 model) ...6C-45 Injection Injection Timing Check (4HF1-2 (4HF1-2 model only) ..6C-46 Injection Timing Adjustment (4HF1-2 model only) ..6C-47 Idling Speed Adjustment (Except 4HF1-2 model) ...6C-48 Idling Speed Check & Adjustment (4HF1-2 model only).................................................................6C-48 INJECTION PUMP DATA ................................... 6C-49 Injection Volume Adjustment (4HF1 Engine)...6C-49 Injection Volume Adjustment (4HF1-2 Engine)6C-54 Injection Volume Adjustment (4HG1 Engine) ..6C-56 ..6 C-56 Injection Volume Adjustment (4HG1-T Engine)6C-59 Injection Volume Adjustment (4HE1-TC Engine) ....6C-62  ANEROID COMPENSATOR ADJUSTMENT .....6C-71 .....6 C-71 Component ...................................................... 6C-71 INJECTION VOLUME ADJUSTMENT................6C-72 4HE1-TC (4HE1-XS) (4HE1-XS) Engine for EURO3 EURO3 ........6C-72 ........6C-72 FUEL TANK ........................................................ 6C-79

Component Component ............ ................... ............. ............. ............. ............. ............. ........ .. 6C-79 Removal.......................................................... Removal .......................................................... 6C-79 Installation.. ..................................................... 6C-79 FUEL GAUGE UNIT ............. ................... ............. ............. ............. ........... .... 6C-81 Component Component ............ ................... ............. ............. ............. ............. ............. ........ .. 6C-81 Removal.......................................................... Removal .......................................................... 6C-81 Installation.. ..................................................... 6C-81  ACCELERATOR CONTROL CABLE ................. 6C-82 Component Component ............ ................... ............. ............. ............. ............. ............. ........ .. 6C-82 Removal.......................................................... Removal .......................................................... 6C-82 Inspection................................................. ....... 6C-82 Installation.. ..................................................... 6C-82  ACCELERATOR PEDAL .................................... 6C-84 Component Component ............ ................... ............. ............. ............. ............. ............. ........ .. 6C-84 Removal.......................................................... Removal .......................................................... 6C-84 Installation.. ..................................................... 6C-84 IDLING CONTROL CABLE ............. ................... ............. ............. ...... 6C-85 Component Component ............ ................... ............. ............. ............. ............. ............. ........ .. 6C-85 Removal.......................................................... Removal .......................................................... 6C-85 Installation.. ..................................................... 6C-85  AIR CLEANER ELEMENT....... ........................... 6C-86 Component Component ............ ................... ............. ............. ............. ............. ............. ........ .. 6C-86 Removal.......................................................... Removal .......................................................... 6C-86 Installation.. ..................................................... 6C-87

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6C-2

FUEL SY SYSTEM

GENERAL DESCRIPTION Caution When working on the fuel system, there are several things to keep in mind: • Any time time the fuel fuel syste system m is being being worke worked d on, disdisconnect the negative battery cable except for those tests where battery voltage is required. • Always Always keep keep a dry chem chemica icall (Class (Class B) fire fire extin extin-guisher near the work area. • Replace Replace all pipes with the same same pipe pipe and fittings fittings that were removed. • Clean Clean and inspe inspect ct “O” rings. rings. Repla Replace ce where where required. • Always relieve relieve the the line line pressure pressure before servicing servicing any fuel system components. • Do not not attempt attempt repairs repairs on the the fuel system until you have read the instructions and checked the pictures relating to that repair.

Description Fuel Filters The Purpose of the fuel filters is to clean the fuel of any dirt particles that can cause wear on the fuel injection nozzle’s sliding surface; and to separate any water from the fuel, which is ever-present from the condensation in the fuel tank. The pre-fuel filter (water separator) is located between the fuel tank and the injection pump. The secondary fuel filter is located between the fuel pump and the injection pump. Pre-Fuel Filter  When the condensed water in the pre-fuel filter (water  separator) comes to the warning level indicated on its plastic body, drain the fluid immediately from the drain plug located bottom of water separator. Injection Pump The fuel injection system includes a fuel tank, fuel hoses and lines, a fuel/water separator, fuel filters, a fuel pump, a Bosch-type in-line fuel injection pump with an internal governor, delivery valves, fuel injection lines and for fuel injection nozzles. The fuel pump, injection pump and the nozzle are manufactured by Bosch AS corporation, but serviced by Bosch. Remove the injection pump and governor assembly as a unit to have it services. Do not open or break any seals on the pump or the warranty is void. The injection pump has an identification plate attached to the pump body.

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FUEL SY SYSTEM

6C-3

Fuel Flow

N6A0817E

Legend  A. Feed B. Return 1. Nozzle 2. Water ater sep separ arat ator  or 

3. Fuel tank 4. Fuel filter   5. Injection pump

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6C-4

FUEL SY SYSTEM

4HF1-2

N6A0818E

Legend 1. Engine 2. Leak off pipe 3. Nozzle Aneroid Compensator Function The bellows in the aneroid compensator is provided with an initial set force by the aneroid compensator spring and is compressed by the push rod C. As the atmospheric pressure drops, the bellows begins to expand against the force of the aneroid compensator spring, which in turn causes the push rod B, through the push rod C and the boost compensator lever F, to move to the left. Then the push rod B comes into contact with the Ushaped lever and, as the expanding bellows over come the force of the cancel spring installed on the U-shaped lever, causes the U-shaped lever to turn clockwise. Because the bottom of the sensor lever is in touch with the torque cam, the torque cam then works as a pivot on which the top of the sensor lever moves to the right together with the U-shaped lever. At the same time, the control rack, which is hooked on the sensor lever, moves toward the governor to reduce fuel injection.

4. Injection pump 5. Fuel filter (sedimeater) 6. Fuel tank

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FUEL SY SYSTEM

6C-5

N6A0819E

Legend 1. Control rack 2. Sensor lever 3. U-shaped lever 4. Torque cam 5. Pu Push rod B 6. Ca Cancel spring

Brief Explanation of Emission and Electrical Control System MITICS (Mechanically Integrated Timing and In jection Control System) 4HE1-TC The Mechanically Integrated Timing and Injection rate Control System (MITICS) utilizes mechanical control, in comparison with TICS systems, which utilize electronic control. MITICS is equipped with the RLD-M type governor, which contains a pre-stroke control mechanism. With this, pre-stroke position (i.e, beginning of static injection) can be varied to control injection timing and injection

7. 8. 9. 10. 11. 12.

Full load set screw Boost compensator lever   Aneroid compensator spring Bellows Re Return spring Pu Push rod C

MITICS was developed in response to the demands of  medium sized diesel engines for low cost, low fuel consumption, high output and cleaner emissions. High injection rates using a short injection interval. • The speed speed at which which the the injecti injection on pump pump plunger plunger risrises slows as engine speed decreases and the pressure inside the injection pipe decreases. Because of this, the nozzle spray deteriorates and makes it impossible to obtain the proper fuel - air mixture. To obtain the proper mixture at low and medium speeds, it is necessary to increase the pressure inside the injection pipes using a short injection interval.

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6C-6

FUEL SY SYSTEM

N6A0820E

Legend 1. Inje Inject ctio ion n pipe pipe pre press ssure ure 2. PE-AD PE-AD typ type e inject injectio ion n pump pump 3. Engi Engine ne spee speed d • The following following figure shows plunger speed and cam lift in relation to cam angle. It can be seen from the graph that plunger speed increases together with cam lift. MITICS varies the beginning of injection position at low and medium speeds so that injection occurs when the plunger speed increases during the latter  half of cam lift (shown by the bold line). At high speeds, injection is performed when the plunger  speed decreases during the first half of cam lift to prevent an excessive increase in injection pipe pressure. This enables high pressures at low and medium speeds with a fast plunger speed. Thus, a fine fuel oil spray is injected into the cylinder from the nozzles within a short time to provide the proper mixture for combustion, helping to increase torque and keep exhaust emissions clean.

N6A0821E

Legend  A. Plunger speed B. Cam lilift 1. Plung Plunger er spee speed d (m/ (m/se sec) c) 2. Cam lif lift (mm (mm)) 3. Cam Cam angl angle e (deg (degre rees es))

Governor (Model RLD-M) 4HE1-TC The RLD-J type governor can be used with the MI, MITICS injection pumps, and was designed to have better control and endurance than the previous RLD type governor.  Although the basic construction is identical to that of the RLD type governor, the RLD-M type is larger to match the applicable pumps’ larger size. Features 1. Variabl Variable e speed speed control control governo governorr with decrea decreased sed lelever reaction force  As with the previous RLD type governor, RLD-M governor control is accomplished using the speed control lever to change the fulcrum of the internal link mechanism. Consequently, as the reaction force of the governor spring does not act directly on the speed control lever, only a very small lever reaction force is exerted on the accelerator pedal.

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FUEL SY SYSTEM

6C-7

Legend 1. Sens Sensor or leve lever  r  2. Torq orque cam cam 3. Cont Contro roll rack rack posit positio ion n (mm) (mm) 4. Pump Pump spe speed ed (r/ (r/mi min) n)

N6A0822E

3. Improved Improved cont control rol through through inte interna rnall guide guide plate plate When the speed control lever is operated, the 2nd supporting lever’s pin moves along the gui de plate. The floating lever connected to the p in thus moves to change the ball joint fulcrum positions. In the intermediate to high speed ranges, the guide plate causes the floating lever to move to increase the lever ratio continuously from 1.1 (idling) — 6 (full speed). This increase in the lever ratio in the intermediate to high speed range improves speed droop.

Legend 1. At max maxim imum um spe speed ed con contro troll 2. At idle idle spee speed d cont contro roll 3. Speed peed contro controll lev lever  er  4. Gove Govern rnor or spri spring ng 5. Link Link mech mechan anis ism m 2. Set torque characterist characteristics ics through through interna internall torque torque cam  At full load, the tip of the sensor lever traces the face of the torque cam to determine the full load rack position and control the full load injection quantity. Consequently, the torque characteristics demanded by the engine can be freely set by changing the shape of the torque cam face.

N6A0824E

Legend 1. Bal Ball join jointt 2. Floa Floati ting ng leve lever  r  3. 2nd suppo support rtin ing g leve leverr pin pin

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6C-8

FUEL SY SYSTEM

N6A0825E

Fuel Filter and Water Separator   A cartridge type fuel filter and a water separator are used along with the in-line type injection pump.  As the inside of the injection injectio n pump is lubricated by the fuel which it is pumping, the fue l must be perfectly clean. The fuel filter and the water separator r emove water particles and other foreign material from the fuel before it reaches the injection pump. The water separator has an internal float. When the float reaches the specified level, a warning light comes on to remind you to drain the water from the separator.

N6A0826E

Legend 1. Bod Body ass assem embl bly y 2. Filt Filter er car cartr trid idge ge

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FUEL SY SYSTEM

6C-9

FUEL FILTER ASSEMBLY (Except 4HF1-2 model) Component

N6A0827E

Legend 1. Fuel pipe

Removal Preparation • Discon Disconnec nectt batte battery ry groun ground d cable cable.. • Tilt Tilt the cab 1. Fuel Pipe 2. Fuel Fuel Filt Filter er Assem Assembl bly y

Installation 1. Fuel Fuel Filt Filter er Assem Assembl bly y Tighten: Fuel filter bracket to 34 N ⋅m (3.5 kg⋅m / 25 lb ⋅ft) 2. Fuel Pipe

2. Fuel filter

 

Pump the primer pump until fuel flow is free of air  bubbles. (Except 4HE1-TC model) • Loosen the bleedin bleeding g plug on the the injection injection pump (2). (4HE1-TC model only) • Oper Operat ate e the the primi priming ng pump pump.. Pump the primer pump until fuel flow is free of air  bubbles. (4HE1-TC model only) • Tighte Tighten n the bleedi bleeding ng plug plug on the injec injectio tion n pump (2). (4HE1-TC model only) • Lock Lock the the primin priming g pump pump cap (1). (1). Notice: Check for fuel leakage from around the injection pump and the fuel filter.

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6C-10

FUEL SYSTEM TEM

N6A0828E

Cartridge Replacement Removal Replacement Procedure 1. Loosen Loosen the used used fuel fuel filter filter by turn turning ing it count countererclockwise with the filter wrench.

N6A0830E

2. Apply Apply a light light coat coat of engin engine e oil to the the O-rin O-ring. g. 3. Supply fuel to to the new fuel fuel filter filter to to facilitate facilitate bleeding. 4. Turn in the new new fuel filter filter until the filter filter O-ring O-ring is is fitfitted against the sealing face. Be very careful to avoid fuel spillage.

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FUEL SYSTEM 2. Drain Drain approx approxima imatel tely y 0.1 liters liters (3.4 (3.4 oz) of water water.. 3. Securel Securely y tight tighten en the drain drain plug. plug. 4. Operate Operate the the primer primer pump pump on the the fuel fuel pump to to bleed bleed the fuel system. 5. Tighten Tighten the air bleedi bleeding ng plug. plug.

N6A0832E

Legend 1. Air Air ble bleed edin ing g plu plug g 2. PrePre-fu fuel el filt filter  er  3. Drai rain level evel 4. Drain plug 6. Start Start the engi engine ne and and check check to be be sure sure no fuel fuel is leaking from the drain plug. 7. Make sure sure that that the warnin warning g light light in the instru instrumen mentt panel is off. (Except 4HE1-TC)

6C-11

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6C-12

FUEL SYSTEM TEM

FUEL FILTER ASSEMBLY (4HF1-2 model only) Component

N6A0834E

Legend 1. Filter cap 2. Lead switch wiring connector 3. Fue Fuel ho hoses

Removal Preparation

4. Fuel filter installing bolt 5. Fuel filter assembly

Installation 1. Fuel Fuel filte filterr asse assembl mbly y

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FUEL SYSTEM

6C-13

Air Bleeding 1. Actuate Actuate the the primi priming ng pump pump (1) to send send the the air in in the fuel system to the injection pump. 2. Loosen Loosen the sedi sedimen menter ter air air bleedin bleeding g plug plug (2) and and operate the priming pump until no bubbles app ear. 3. Tighte Tighten n the air air bleedin bleeding g plug plug complet completely. ely. 4. Try to start start the engin engine. e. If the the engine engine is is not star started ted within 10 seconds, air bleeding should b e conducted once again. 5. Check Check that that there there is no fuel fuel leak leak,, and then then tight tighten en the priming pump completely.

N6A0836E

Legend 1. Air Air ble bleed edin ing g plu plug g

Reassembly 1. Fit the the sedime sedimenter nter/ce /center nter in a new new cartrid cartridge. ge. 2. Clean Clean the cartri cartridge dge mounti mounting ng surfac surface e of the filter  filter  body so that the new cartridge can be seated completely. 3. Apply engine engine oil thinly thinly to the the new cartridge cartridge O-ring. O-ring. 4. Fill the new cartridge cartridge with light light oil to to facilitate facilitate air  bleeding.

N6A0032E

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6C-14

FUEL SYSTEM TEM

INJECTION NOZZLE ASSEMBLY Component

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FUEL SYSTEM 4HE1-TC (Engine)

6C-15

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6C-16

FUEL SYSTEM TEM MPa (kg/cm2/psi)

Injection Nozzle Opening Pressure 4HF1/4HF1-2/4HG1

18.1 (185/2,631)

4HE1-TC

21.6 (220/3,128)

4HG1-T

1st

18.1 (185/2,631)

2nd

21.1 (215/3,057)

N6A0841E

4. Injec Injecti tion on Nozz Nozzle le Asse Assemb mbly ly Mark the nozzle holder assemblies fitting positions by tagging each nozzle holder assembly with the cylinder number from which it was removed.

N6A0843E

Spray Pattern Check the spray pattern Refer to the illustration.

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FUEL SYSTEM

6C-17

Leakage Hold the tester handle to about 2,070 kPa (21 kg/cm 2/ 300 psi) below the opening pressure. If no drops of fuel fall from the nozzle tip within 10 seconds, the nozzle is not leaking. Chatter   An easily audible chatter at all pump lever speeds should be heard. WARNING: Warning: TEST FLUID FROM THE INJECTION NOZZLE WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN EASILY PUNCTURE A PERSON’S SKIN. KEEP  YOUR HANDS AWAY FROM THE INJECTION NOZZLE TESTER AT ALL TIMES.

Disassembly Clamp the injection nozzle holder in a vice. N6A0846E

3. Inje Inject ctio ion n Noz Nozzl zle e Keep the nozzle along with the needle valve sepa-

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6C-18

FUEL SYSTEM TEM

Inspection Injection Nozzle Needle 1. Remove Remove the the nozzl nozzle e from from the nozz nozzle le body. body. 2. Careful Carefully ly wash wash the nozzl nozzle e needle needle and the the nozzle nozzle body in clean diesel fuel. 3. Check Check that that the nozzl nozzle e needle needle moves moves smoot smoothly hly ininside the injection nozzle body. If the nozzle does not move smoothly, it must be repaired (See “Nozzle Lapping Procedure” below).

Nozzle Body and Needle Valve Check the nozzle body and the needle valve for damage and deformation. The nozzle and body assembly must be replaced if either of these two conditions are discovered during inspection. Notice: New nozzles must be cleaned in a solvent to remove protective coating. The nozzle body and needle mu st always be replace as an assembly.

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FUEL SYSTEM

6C-19

Legend 1. Flange 2. Ret Retainin ining g nut nut 3. Inje Inject ctio ion n nozz nozzle le 4. Spacer   5. Sprin pring g seat eat 6. Nozz Nozzle le spr sprin ing g 7. Adju Adjust stin ing g shim shim 8. Nozz Nozzle le hol holde derr body body 1. 2. 3. 4.

Nozz Nozzle le Hol Holde derr Body Body Adju Adjust stin ing g Shi Shim Nozz Nozzle le Spri Spring ng Spri Sprin ng Se Seat

5. Spacer   6. Inje Inject ctio ion n Nozz Nozzle le Install the nozzle dowel pin with it set to the dowel hose of the nozzle holder body.

N6A0846E

Remove the injection nozzle holder from the vice. 8. Flange

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6C-20

FUEL SYSTEM TEM

Opening Pressure Adjustment 1. Clamp Clamp the inje injectio ction n nozzle nozzle holder holder (1) in in a vise (2). (2). 2. Use a wrench to remove remove the injectio injection n nozzle nozzle retainretaining nut (3).

9. Attach Attach the injec injectio tion n nozzle nozzle holder holder to the inje injecti ction on nozzle tester. 10. Apply Apply pressur pressure e to the nozzl nozzle e tester tester to check check that that the injection nozzle opens at the specified pressure. If the injection nozzle does not open at the specified pressure, install or remove the appropriate number or adjusting shims to adjust it. Removing or installing one shim will increase or  decrease the nozzle opening pressure approximately 370 kPa (3.77 kg/cm 2 / 53.6 psi).  Adjusting Shim Availability

mm (in)

Range

0.5 — 1.5 (0.02 — 0.06)

Increment

0.025 (0.001)

Total Number of Shims

41

Spray Pattern Check the spray condition. Refer to the illustration.

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FUEL SYSTEM

6C-21

Reassembly and Opening Pressure Adjustment

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6C-22

FUEL SYSTEM TEM

2. Full needle needle valve valve lift lift confir confirmat mation ion • Confir Confirm m the full full need needle le valve valve lift lift in accor accordanc dance e with the closed method. 3. PrePre-li lift ft conf confirm irmat atio ion n • Confir Confirm m pre-lif pre-liftt in accor accordan dance ce with with the the closed closed method. Caution: If not as specified, replace the nozzle assembly, lift piece, pins and spacer using the nozzle service kit. Adjustment Service Data (4HG1-T only)

4. Second Second nozzle nozzle openi opening ng pressur pressure e confirma confirmatio tion n • Confirm Confirm the seco second nd nozzl nozzle e openin opening g pressu pressure re in accordance with the closed method. 5. Second Second nozzl nozzle e openin opening g pressur pressure e adjust adjustment ment • Adjust Adjust the the secon second d nozzle nozzle opening opening press pressure ure ususing the shim. 6. Fina Finall insp inspec ecti tion on • Confirm Confirm the cond conditi ition on of the the fuel fuel spray spray with with the the nozzle and nozzle holder assembled.

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FUEL SYSTEM 3. Install Install the collar, collar, second second spring, spring, shim, spring seat and push rod in the nozzle holder.

6C-23

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6C-24

FUEL SYSTEM TEM • First First nozzle nozzle openin opening g pressure pressure adjus adjustin ting g shims Part No. (ISUZU)

Thickness mm (in)

115349-0420

0.40 (0.0157)

115349-0430

0.50 (0.0197)

115349-0440

0.52 (0.0205)

115349-0450

0.54 (0.0213)

115349-0460

0.56 (0.0220)

115349-0470

0 58 (0 0228)

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FUEL SYSTEM

6C-25

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6C-26

FUEL SYSTEM TEM

Caution: • Secure Secure the the dial dial gauge gauge so that that a stroke stroke of 2 mm (0.08 in) can be measured. • Do not over-t over-tigh ighten ten the the nut as the dial dial gauge gauge shaft shaft may jam. (Confirm from the dial gauge that the shaft moves smoothly.)

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FUEL SYSTEM Pre-lift Confirmation

6C-27

Read the dial gauge at first nozzle opening pressure

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6C-28

FUEL SYSTEM TEM

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FUEL SYSTEM gauge indicates the specified needle valve lift (usu-

6C-29

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6C-30

FUEL SYSTEM TEM condition, seat oil tightness and each part for oil

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FUEL SYSTEM

6C-31

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6C-62

FUEL SYSTEM TEM

Injection Volume Adjustment (4HE1-TC Engine) Test Conditions 4HE1-TC Engine Item

Condition

Injection nozzle and holder assembly

Bosch AS Part No.: 105118-6462

Injection nozzle

Bosch AS Part No.: 105017-2181

Nozzle holder

Bosch AS Part No.: 105048-4510

Inject Injection ion nozzle nozzle openin opening g pressur pressure e

kPa (kg/cm (kg/cm2 / psi)

18,142 (185 / 2,631)

Injection line dimensions Inside diameter

mm (in)

3.0 (0.118)

Outside diameter

mm (in)

8.0 (0.315)

Length

mm (in)

600 (23.6)

Fuel delivery pressure

kPa (kg/cm2 / psi)

Test fuel Test fuel temperature

254.9 (2.6 / 36.97) SAE Standard Test Diesel Fuel (SAE J967d) ISO Standard Test Diesel Fuel (ISO 4113)

°C (°F)

Identification numbers

Identification Plate and Number  Use the data following the injection pump identification number to adjust the injection volume.

40 — 45 (104 — 113) 107492-1023 107492-1062 107492-1032 107492-1100 107492-1110 107492-1120 107492-1130 897212-9351 (ISUZU NO.)

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FUEL SYSTEM

6C-63

Injection Volume and Governor Performance Diagram Ident Identif ific icat atio ion n Numb Number ers s

: 107492 107492-1 -1110 110

[4HE1-TC Engine] Pre-stroke

: No. 1 plunger 4.0±0.03 mm (0.1575±0.0012 in)

Injection order

: 1 — 3 — 4 — 2 (interval 90 °±15′) Plungers are numbered from the Governor side

Tapp appet cl cleara arance

: Bo Bolt ad adjustment ent ty type

: Mor More e th than 0.3 mm (0 (0.0118 in in) fo for al all cy cylinder ders.

: Shim adjustmen adjustmentt type

: Manually Manually rotate rotate the the camshaft camshaft 2 — 3 times times and confirm that itit rotates smoothly.

Injection Volume Pump speed (r.p.m.)

Injection volume (cc/ 1000 strokes)

Variance (%)

1,000

82.5±1.6

±4

H

400

19±1.5

±14

Z

500

—

—

 A

1,000

82.5±1

—

B

1,450

92.5±2

—

C

500

67

—

D

1,450

89.5

—

I

150

220

—

 Adjusting point

Remarks Basic

Basic

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6C-64

FUEL SYSTEM TEM

Governor Adjustment

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FUEL SYSTEM

6C-65

Injection Volume and Governor Performance Diagram Identi Identific ficati ation on Numbers Numbers

: 107492107492-1023 1023 / 107492107492-110 1100 0

[4HE1-TC Engine] Pre-stroke

: No. 1 plunger 4.0±0.03 mm (0.1575±0.0012 in)

Injection order

: 1 — 3 — 4 — 2 (interval 90 °±15′) Plungers are numbered from the Governor side

Tapp appet cl cleara arance

: Bo Bolt ad adjustment ent ty type

: Mor More e th than 0.3 mm (0 (0.0118 in in) fo for al all cy cylinder ders.

: Shim adjustmen adjustmentt type

: Manually Manually rotate rotate the the camshaft camshaft 2 — 3 times times and confirm that itit rotates smoothly.

Injection Volume Pump speed (r.p.m.)

Injection volume (cc/ 1000 strokes)

Variance (%)

1,000

107.5±1.6

±4

H

400

22±1.5

±10.0

Z

510

—

—

 A

1,000

107.5±1

—

B

1,200

112.5±2

—

C

500

(78)

—

D

1,200

(103)

—

I

150

(235)

—

 Adjusting point

Remarks Basic Basic

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6C-66

FUEL SYSTEM TEM

Governor Adjustment

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FUEL SYSTEM

6C-67

Injection Volume and Governor Performance Diagram Identi Identific ficati ation on Numbers Numbers

: 107492-1 107492-1062 062 / 107492 107492-112 -1120 0 / 897212-9 897212-9350 350 (ISUZU (ISUZU NO.) NO.)

[4HE1-TC Engine] Pre-stroke

: No. 1 plunger 4.0±0.03 mm (0.1575±0.0012 in)

Injection order

: 1 — 3 — 4 — 2 (interval 90 °±15′) Plungers are numbered from the Governor side

Tapp appet cl cleara arance

: Bo Bolt ad adjustment ent ty type

: Mor More e th than 0.3 mm (0 (0.0118 in in) fo for al all cy cylinder ders.

: Shim adjustmen adjustmentt type

: Manually Manually rotate rotate the the camshaft camshaft 2 — 3 times times and confirm that itit rotates smoothly.

Injection Volume Pump speed (r.p.m.)

Injection volume (cc/ 1000 strokes)

Variance (%)

1,000

107.5±1.6

±4

H

400

22±1.5

±14

Z

510

—

—

 A

1,000

107.5±1

—

B

1,400

121.5±2

—

C

500

78

—

D

1,400

103

—

I

150

235

—

 Adjusting point

Remarks Basic Basic

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6C-68

FUEL SYSTEM TEM

Governor Adjustment

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FUEL SYSTEM

6C-69

Injection Volume and Governor Performance Diagram Ident Identif ific icat atio ion n Number Numbers s

: 1074910749-10 1032 32 / 107492 107492-11 -1130 30

[4HE1-TC Engine] Pre-stroke

: No. 1 plunger 4.0±0.03 mm (0.1575±0.0012 in)

Injection order

: 1 — 3 — 4 — 2 (interval 90 °±15′) Plungers are numbered from the Governor side

Tapp appet cl cleara arance

: Bo Bolt ad adjustment ent ty type

: Mor More e th than 0.3 mm (0 (0.0118 in in) fo for al all cy cylinder ders.

: Shim adjustmen adjustmentt type

: Manually Manually rotate rotate the the camshaft camshaft 2 — 3 times times and confirm that itit rotates smoothly.

Injection Volume Pump speed (r.p.m.)

Injection volume (cc/ 1000 strokes)

Variance (%)

900

78±1.6

±4

H

400

19±1.5

±14

Z

500

—

—

 A

900

78±1

—

B

1,450

89.5±2

—

C

500

67.5

—

D

1,450

91.5

—

E

700

78

—

I

150

220

—

 Adjusting point

Remarks Basic Basic

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6C-70

FUEL SYSTEM TEM

Governor Adjustment

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FUEL SYSTEM

6C-71

ANEROID COMPENSATOR ADJUSTMENT Component

N6A0961E

Legend 1. Setting screw

2. Between 1.4 — 1.7 mm (0.055 — 0.067 in) at sea level (adjust by setting screw)

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6C-72

FUEL SYSTEM TEM

INJECTION VOLUME ADJUSTMENT 4HE1-TC (4HE1-XS) Engine for EURO3 Test Condition Item

Condition

Injection nozzle and holder assembly

Bosch AS Part No.: 105118-6831

Injection nozzle

Bosch AS Part No.: 105017-2930

Nozzle holder

Bosch AS Part No.: 105048-4430

Inject Injection ion nozzle nozzle openin opening g press pressure ure

MPa (kg/ (kg/cm cm2 / psi)

20.7 (211 / 3,000)

Injection line dimensions Inside diameter

mm (in)

3.0 (0.118)

Outside diameter

mm (in)

8.0 (0.315)

Length

mm (in)

600 (23.6)

Fuel delivery pressure

kPa (kg/cm2 / psi)

Test fuel Test fuel temperature Identification numbers

254.9 (2.6 / 36.97) SAE Standard Test Diesel Fuel (SAE J967d) ISO Standard Test Diesel Fuel (ISO 4113)

°C (°F)

40 — 45 (104 — 113) 107492-1162 897225-4322 (ISUZU No.)

Injection Timing Pre-stroke

: No. 1 plunger 4.0±0.03 mm (0.1575±0.0012 in)

Injection order

: 1 — 3 — 4 — 2 (interval 90 °±15′) Plungers are numbered from the Governor side

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FUEL SYSTEM

6C-73

Pre-stroke adjustment  Adjust No.1 cylinder’s start of static injection usi ng the shim (1). Individual cylinder’s injection order adjustment  Adjust difference d ifference between each cylinder’s injection angle based on that of the No.1 cylinder using the shim (1).

N6A0962E

N6A0963E

Measuring pre-stroke output voltage 1. Install Install the the measuri measuring ng device device (P/N 105782 105782-64 -6420). 20). 2. Remove Remove the the setscre setscrew w (3) (P/N (P/N 157927 157927-28 -2820) 20) and and install the air bleeder bolt. 3. Screw Screw in scre screw w (4) (P/N (P/N 15792 157927-33 7-3321) 21) and and meameasure the No 1 cylinder’s output voltage for pre-

Advice If measuring device (P/N 105782-6420) is removed, the output voltage (a1, a2) should be remeasured. Minimum advance angle adjustment stopper adjustment 1. Remove Remove the the screw screw (4) (4) (P/N 15792 157927-33 7-3321) 21) and and install minimum advance angle adjustment stopper. 2. Screw Screw in minim minimum um advanc advance e angle angle adjus adjustme tment nt stopper until No 1 cylinder’s pre-stroke is 3.84 — 3.90 mm (0.1512 — 0.1535 in). Then, tighten locknut to specified torque. 3. Measur Measure e the outpu outputt voltage voltage (c) (c) at this this time. time. Solenoid switch adjustment

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6C-74

FUEL SYSTEM TEM

Governor Ad justment Governor adjustment

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FUEL SYSTEM Boost compensator adjustment 1. Selec Selectt a push push rod rod so so (C) (C) = 37.5 37.5±0.5 mm (1.48 ±0.02 in) at full boost pressure. ((C) is the distance from the end face of the housing to top of the lever.) 2. Adjust Adjust the boost boost compe compensat nsator or stroke stroke using using screw screw (A). (0 boost pressure position adjustment)  Adjust the beginning of b oost compensator operation by adjusting the notch adjusting nut (B).

N6A0965E

Legend 1. Top of lever  ever  2. Push ro rod 3. Boost Boost

inlet inlet

6C-75

6. Confirm Confirm that that the pre-stroke pre-stroke output voltage voltage is within the range b1 — b2. Confirmation point

b

Pre-stroke (mm (in))

Output voltage (actual)

Remarks

3.24 (0.1276)

b1

+ tolerance

3.04 (0.1197)

b2

− tolerance

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6C-76

FUEL SYSTEM TEM

Injection Quantity

 Adjusting point

Rack position (mm (in))

Pump speed (r/min)

Injection q’ty (cm3 /1,000 strokes)

Max. variation between cylinders

Fixed

Pre-stroke at adjustment

—

16.1 (0.6339)

1,000

124±1.6

±4

Rack

a1 — a2 (v)

Z

8.7±0.5 (0.3425± 0.0197)

 A

R1 (16.1 (0.6339))

B

R1+0.45 (0.0177)

D*

16.15±0.1 (0.6358± 0.0039)

585

1,000

1,150

1,150

14±1.5

124±1

123.5±2

—

±14

—

—

—

D*: Aneroid compensator actuator adjustment point

FICD Adjustment 1. Stop Stop the the inje injecti ction on pump pump.. 2. Hold speed control control lever lever against against idling stopper stopper bolt. bolt. 3. Adjust Adjust cleara clearance nce betwe between en FICD actu actuato atorr lever and and

Remarks

Basic

Cylinder variation adjustment standard Cylinder variation adjustment standard

Rack

c (v)

Lever

a1 — a2   (v)

Boost press. kPa (mmHg/ Basic psi)  Above 44.0 (330/6.38)

Measure

Boost press. kPa (mmHg/ psi)  Above 44.0 (330/6.38)

Measure

Boost press. kPa (mmHg/ psi)  Above 44.0 (330/6.38) Negative press. kPa (mmHg/psi) 53.3 (400/7.73)

Lever

Lever

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FUEL SYSTEM

6C-77

Aneroid Compensator Actuator Adjustment (In jection Quantity Decrease) Notice: Set this actuator after adjusting the full rack position. 1. Stop Stop inje inject ction ion pump. pump. 2. Adjust wire nut so full load set lever lever contact contacts s full load set bolt and aneroid compensator actuator  wire is not loose. Then, fix the nut. 3. Apply Apply 53.3 53.3 kPa (400 (400 mmHg/ mmHg/7.73 7.73 psi) negat negative ive pressure to aneroid compensator, set pump speed at 1,150 r/min.

N6A0968E

Legend 1. Nut

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6C-78

FUEL SYSTEM TEM

 At this time, hold control contro l rack using a spanner (to prevent the rack from bending). Specified torque: 3.4 — 4.9 N⋅m (0.35 — 0.5 kg ⋅m/2.5 — 3.6 lb⋅ft) 4. While pulling stop lever, install install rack rack sensor sensor to to rack rack sensor core. 5. Tighten Tighten the two two flng flnge e fixing fixing screws screws.. Specified torque: 6.9 — 8.8 N ⋅m (0.7 — 0.9 kg⋅m/5.1 — 6.5 lb⋅ft)) 6. Connec Connectt the rack rack sensor sensor wire wire harne harness ss to const constant ant voltage power supply and digital voltmeter. 7. Turn const constant ant volta voltage ge power power supply supply power power switc switch h ON and set it to DC 5 ±0.01V. 8. Apply Apply at least least 44.0 44.0 kPa (330 (330 mmHg/6 mmHg/6.38 .38 psi) psi) boost boost pressure, set pump speed at N = 1,000 r/min, and hold speed control lever against the full speed stopper bolt. 9. Confir Confirm m the rack rack sensor sensor output output volt voltage age from from the digital voltmeter. (Vist = 2.77 ±0.28V) 10. Confirm Confirm that that the volt voltage age chang changes es when when the speed speed control lever is moved to the idle and full sides.

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FUEL SYSTEM

FUEL TANK Component

6C-79

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6C-80

FUEL SYSTEM TEM

Tighten: Fuel tank bracket to 55 N ⋅m (5.6 kg⋅m / 41 lb ⋅ft)  Also, when mounting the fuel tank to the bracket, place the packing section attached to the fuel tank securely on the bracket. 2. Band • Tigh Tighte ten n the the band band to 12 N⋅m (1.2 kg⋅m /104 lb⋅in) 3. Fuel Fuel Gaug Gauge e Unit Unit Con Conne nect ctor  or  • Connec Connectt the the fuel fuel gauge gauge unit unit conn connect ector. or. 4. Fuel Fuel Retu Return rn Hose Hose 5. Fuel Fuel Feed Feed Hos Hose • Set the the hose hose to to the pipe pipe more more than than 25 mm mm (0.98 (0.98 in) deep. 6. Evap Evapo o Fue Fuell Hos Hose e • Fill Fill the the fue fuell to the fuel fuel tank tank.. • Conne Connect ct bat batte tery ry gro ground und cable cable..

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FUEL SYSTEM

6C-81

FUEL GAUGE UNIT Component

N6A0972E

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6C-82

FUEL SYSTEM TEM

ACCELERATOR CONTROL CABLE Component

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FUEL SYSTEM 5. Adjust Nu Nut • Attach Attach the the end end tip of the the wire wire to to the engine engine concontrol lever. • Pull Pull the outer outer cable cable gentl gently y towar toward d the front front of  the vehicle, and provide the engine control wire and the accelerator control wire an appropriate play before fastening the clamp with a nut. Tighten: Nut to 8 N ⋅m (0.8 kg⋅m /69 lb ⋅in) • Check Check to see see if the the injec injectio tion n pump lever lever is at at the

6C-83

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6C-84

FUEL SYSTEM TEM

ACCELERATOR PEDAL Component

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FUEL SYSTEM

IDLING CONTROL CABLE Component

6C-85

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6C-86

FUEL SYSTEM TEM

AIR CLEANER ELEMENT Component

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FUEL SYSTEM

6C-87

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6C-88

FUEL SYSTEM TEM