Isuzu N-Series. Service manual — part 731
6E-346 Engine Control System (4HK1)
4. Install the fuel leak off hose to the fuel leak off pipe.
5. Install the air intake pipe.
Notice:
• Carefully check for fuel leak after starting the
engine.
• After the fuel pressure limiter is replaced, clear the
trouble code and make sure the fuel pressure limiter
operates normally using a scan tool.
Fuel Rail Replacement
Removal Procedure
WARNING:
TO PREVENT LEAKED FUEL FROM CATCHING
FIRE, DO NOT WORK WHILE THE ENGINE IS HOT.
Preparation:
• Pour detergent into a steam cleaner, and throughly
wash around the sensor and the fuel rail.
• Remove water completely using air blow.
Notice:
Make sure that foreign matter will be prevented from
getting in.
1. Remove the air intake pipe.
• Disconnect the connector for the intake air
temperature sensor.
2. Remove the fuel leak off hose from the leak off
pipe.
• Cover the removed fuel hose, keep it facing
upward and secure it using wire, etc.
3. Disconnect the fuel rail pressure sensor harness
connector.
4. Remove the EGR valve and the EGR adapter.
5. Tape the EGR case holes shut to prevent the entry
of foreign material.
Legend
1. EGR Adapter
2. EGR Valve
6. Remove the injection pipe clip and remove the
injection pipes.
Important:
Loosen the injection pipes gradually not to scatter high
pressure fuel.
N6A6386E
N6A6368E
Engine Control System (4HK1) 6E-347
Legend
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
7. Remove the fuel pipe.
Important:
Loosen the fuel pipe gradually not to scatter high
pressure fuel.
8. Remove the clips and the fuel leak off pipe.
Legend
1. Fuel Pipe
2. Fuel Leak-Off Pipe
9. Remove the fuel rail and the fuel rail bracket.
• Do not remove the flow damper. The dampers
should always remain in the fuel rail.
• Take care not to damage the connector unit of
the pressure sensor.
Legend
1. Fuel Rail Bracket
2. Fuel Rail
Disassembly
1. Remove the fuel pressure limiter.
2. Remove the fuel rail pressure sensor.
N6A6128E
N6A6383E
N6A6384E
6E-348 Engine Control System (4HK1)
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter
4. Flow Damper
Reassembly
1. Install the fuel pressure limiter.
Tighten:
Fuel pressure limiter to 172 N
⋅m (17.5 kg⋅m / 127
lb
⋅ft)
2. Install the fuel rail pressure sensor.
Tighten:
Fuel rail pressure sensor to 98 N
⋅m (10 kg⋅m / 72
lb
⋅ft)
Installation Procedure
1. Tighten the fuel rail bracket using the specified
mounting torque.
Tighten:
Nuts to 19 N
⋅m (1.9 kg⋅m / 14 lb⋅ft)
2. Tighten the fuel rail using the specified mounting
torque.
Tighten:
Bolts to 19 N
⋅m (1.9 kg⋅m / 14 lb⋅ft)
Legend
1. Fuel Rail Bracket
2. Fuel Rail
3. Tighten the fuel leak off pipe (1) using the
mounting eyebolt and the clips using the specified
torque.
Tighten:
(2): 18 N
⋅m (1.8 kg⋅m / 13 lb⋅ft)
(3): 12 N
⋅m (1.2 kg⋅m / 9 lb⋅ft)
(4): 8 N
⋅m (0.8 kg⋅m / 69 lb⋅in)
4. Tighten the fuel pipe (5) using the mounting sleeve
nut and the clip using the specified torque.
Tighten:
(6): 44 N
⋅m (4.5 kg⋅m / 33 lb⋅ft)
(7): 6 N
⋅m (0.6 kg⋅m / 52 lb⋅in)
(8): 44 N
⋅m (4.5 kg⋅m / 33 lb⋅ft)
5. Install the fuel leak off hose to the fuel leak off pipe.
1
3
2
4
N6A6385E
N6A6384E
N6A6386E
Engine Control System (4HK1) 6E-349
6. Tighten the injection pipe and the clip using the
specified mounting torque.
Tighten:
Injection pipe sleeve nut to 44 N
⋅m (4.5 kg⋅m / 33
lb
⋅ft)
Injection pipe clip to 6 N
⋅m (0.6 kg⋅m / 52 lb⋅in)
• Apply a thin coat of engine oil on the periphery
of the sleeve nut on the injector side and
assemble.
Legend
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
7. Connect the fuel rail pressure (FRP) sensor
connector.
8. Install the gasket to the EGR valve and tighten the
bolts to the specified torque.
Tighten:
Bolts to 24 N
⋅m (2.4 kg⋅m / 17 lb⋅ft)
9. Install the gasket to the EGR adapter and tighten
the bolts to the specified torque.
Tighten:
Bolts to 24 N
⋅m (2.4 kg⋅m / 17 lb⋅ft)
Legend
1. EGR Adapter
2. EGR Valve Gasket
3. EGR Valve
4. EGR Valve Gasket
10. Install the air intake duct.
• Connect the connector for the intake air
temperature sensor.
Fuel Supply Pump Replacement
Removal Procedure
Important:
The fuel supply pump must be timed to the engine.
1. Remove the intake pipe and the intake throttle
valve.
2. Remove the fuel pipe and fuel leak-off pipe.
N6A6128E
N6A6371E
N6A6121E
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