Isuzu N-Series. Manual - part 729

6E-338    Engine Control System (4HK1) 

Installation Procedure

1. Install the ECT sensor (1).

2. Connect the ECT sensor connector.
3. Replenish any lost engine coolant.

Fuel Injector Replacement / Fuel Injector ID
Code Data Programming

Important:
The Fuel Injector ID Code Data Programming MUST be
done when the fuel injector is being replaced. The Fuel
Injector ID Code information MUST be recorded before
assembling the cylinder head cover.

Removal Procedure

1. Remove the engine harness, the throttle position

sensor, the EGR valve, the pressure sensor, and
all of the fuel injector connectors.

2. Remove the EGR valve and the EGR adapter.

3. Tape the EGR case holes shut to prevent the entry

of foreign material.

Legend

1. EGR Adapter
2. EGR Valve

 

4. Remove the sound insulation cover.
5. Remove the head cover.

Legend

1. Sound Insulation Cover (For Europe)
2. Head Cover

 

6. Loosen the fuel injector terminal nuts.
7. Loosen the fuel injector harness bracket bolts.

Remove the inside connector and the harness
bracket.

8. Remove the fuel injector leak-off pipe.
9. Remove the lower cover.

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 Engine Control System (4HK1)    6E-339

Legend

1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak-Off Pipe

 

10. Remove the fuel injection pipe clips and the

injection pipes. 

Legend

1. Fuel Injection Pipe
2. Pipe Clip

 

11. Loosen the fuel injector clamp fixing bolts and

remove the fuel injectors.

If the fuel injectors are difficult to remove, use the fuel
injector remover. Install the fuel injector remover to the
leak-off pipe attachment part on the fuel injector. Use a
sliding hammer to force the fuel injector clamp off the
fuel injector.

Caution:
Do not remove the fuel injector sleeve.

Special tools
Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)

Legend

1. Sliding Hammer
2. Remover
3. Fuel Injector Assembly

 

12. Mark each fuel injector with the number of the

cylinder from which it was removed. Store the fuel
injectors in a safe place. Position the fuel injector
so that the nozzle is protected.

Caution:

• Do not tamper with the electromagnetic portion of

the fuel injector. Reduced electromagnetic function
will result in injector failure.

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6E-340    Engine Control System (4HK1) 

Recording from the each fuel injector ID plate
Record 24 figures of each fuel injector ID plate. The
correct order for the fuel injector ID code for the
following illustration is as follows:
56 00 D1 CA 00 00 EC 00 23 14 21 B7

Legend

1. Fuel Injector ID Plate
2. Fuel Injector ID Code
3. Fuel Injector

 

Installation Procedure
Important:
Install each of the fuel injectors on its original position.
(the cylinder from which it was removed)

1. Install a new gasket and O-ring to each of the fuel

injector clamps. Refer to the illustration.

Legend

1. Gasket
2. Fuel Injector
3. Bolt
4. Fuel Injector Clamp

 

2. Apply molybdenum to the threads and seating

surfaces of the clamp bolts.

3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface

of the fuel injector side sleeve nuts.

6. Install the fuel injection pipes to the position shown

in the illustration.

7. Use a spanner to carefully the sleeve nuts until the

fuel injection pipes contact the fuel injector and
common rail.

8. Tighten the fuel injection pipe clips to the specified

torque.

Tighten:
Clips to 6 N

⋅m (0.6 kg⋅m / 52 lb⋅in)

D1CA
EC00
2100
B7

5600
0000
2314
0000

1

2

3

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 Engine Control System (4HK1)    6E-341

Legend

1. Fuel Injection Pipe
2. Pipe Clip

 

9. Final tighten the injection clamp bolts to the

specified torque.

Tighten:
Bolts to 30 N

⋅m (3.1 kg⋅m / 22 lb⋅ft)

10. Tighten the injection pipes to the specified torque.

Tighten:
Injection pipes to 44 N

⋅m (4.5 kg⋅m / 33 lb⋅ft)

Legend

1. Clamp Bolt
2. Sleeve Nut

 

11. Install the nozzle leak off pipes together with the

new gaskets. Tighten the pipes to the specified
torque.

Tighten:
Pipes to 12 N

⋅m (1.2 kg⋅m / 104 lb⋅in)

12. Install the fuel injector harness connectors. Work

from the inside out.

13. Install the harness bracket and tighten the bolts to

the specified torque.

Tighten:
Bolts to 48 N

⋅m (4.9 kg⋅m / 35 lb⋅ft)

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