Introduces Install of the Isuzu Engine 4JJ1 Euro 4 N Series common Rail

     This article mainly introduces Install
of the Isuzu   Engine 4JJ1 Euro 4 N Series common Rail

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  1. Install the space rubber, common rail bracket, and common rail, and tighten them at the specified torque.
Tightening torque:25 N-m(2.5kgm/18 b-t)
2. Install the injection pipe and tighten the sleeve nut
(1) at the specified torque.
Tightening torque:25 Nm (2.5 kgm/18 lbt)

3. Install the harness connector of the fuel pressure sensor.
4. Connect the fuel hose(1).

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5. Install the fuel feed pipe(1) and tighten the sleeve nut at the specified torque.
Tightening torque:44 N.m(4.5kgm/33 bt)

6. Install the fuel leak-off pipe(1), and tighten the ayebolt at he specied torque. aC gml e Tightening torque:10 N-m(1.0kg-m/87 lb-in)

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7. Install the engine oil level gauge and guide tube, and tighten the fixing bolt at the specified torque.
· Apply engine oil to the O-ring of the guide tube.
Tightening torque:25 N-m(2.5kg-m/18 ib-ft)
8. Install the left side noise cover.
9. Install the dropping register harness connector.
10. Install the air duct.
NOTE: Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.
. Install the air duct between air cleaner and turbocharger.
· Use a new hose clamp, align it with the marking.
Tightening torque Air cleaner side:8 N-m(0.8 kg-m/69 lb-in)
Turbocharger side:6.4 N-m (0.65 kg-m/56.4 lb-in)
NORMA W3 Clamp
8 Nm (0.8 kgm/69 b-in)
NORMA W1 Clamp
11. Install the air intake duct and hose.
List of Tightening Torques

NOTE: Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.
· Install the duct and hose between the intake throttle valve and intercooler.
· Use a new hose clamp, align it with the marking Tightening torque:8N-m (0.8kg-m/69 lb in)
12. Connect the connector of the boost sensor.

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Introduces Removaland of the Isuzu Engine 4JJ1 Euro 4 N Series common Rail

 

         This article mainly introduces Removaland  of the Isuzu   Engine 4JJ1 Euro 4 N Series common Rail

Legend
1. Injection pipe(#1-#4)5. Common rail(Fuel rail) bracket
2. Fuel feed pipe
3. Injection pipe clip7. Fuel leak-off pipe
4. Common rail(Fuel rail)
Including the inside of the injector, the holes and gaps that are the fuel paths for the fuel system have anextremely precise finish. Therefore, because there is the possibility of damage if foreign material becomes mixed in, cover the cap after removing parts, etc. to prevent the entry of foreign material.
Removal
1. Disconnect the air intake duct and hose.
· Disconnect the boost sensor connector (1), and remove the air intake duct together with the hose.

2. Kemove the air duct(air cleaner-turbocharger alr duct).
3. Remove the left side noise cover.
· Remove the harness connector of the dropping register, and remove the noise cover.
4. Remove the harness connector of the fuel pressure sensor(1).

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5. Remove the engine oil level gauge and guide tube.
6. Remove the leak-off pipe(1).

NOTE:
Do not reuse the leak-of pipe gasket

7. Remove the fuel feed pipe(1).

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NOTE: Do not reuse the fuel feed pipe
8. Remove the fuel hose(1).
· Keep the disconnected fuel hose in clean, so that dust should not adhere.

9. Remove the sleeve nut(1) of the injection pipe from the common rail.

NOTE: Do not reuse the injection pipe
10.Remove the common rail and the common rail bracket.
NOTE:
·Do not hold the pressure limiter or pressure sensor.
Make sure to hold the common rail unit.
·Be careful not to damage the pressure sensor connector.

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Legend
1. Common rail(Fuel rail)
2. Common rail(Fuel rail) bracket
3. Space rubber
4. Pressure sensor
5. Pressure limiter

Installation of Fuel Pump for Isuzu 4JJ1 Euro 4n Series Engine

This article mainly introduces the Installation the Isuzu engine oil pump

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Installation
1. Install the O-ring to the supply pump.
· Apply soapy water to the O-ring.
2. Install the supply pump.
a. Install the space rubber A (4) to the cylinder block.
b. Insert the space rubber B(2) into the supply pump bracket(3).
c. Install the supply pump bracket (3) in the following sequence.
1. Temporarily tighten the nuts and bolt on the gear case side until they are firmly attached to the gear case.
2. Temporarily tighten the bolts on the cylinder block side until they are firmly attached to the cylinder block.
3. Tighten the nuts and bolt on the gear case side to the specified torque.
Tightening torque:25 N,m(2.5kg-m/18 lbft)
4. Tighten the bolts on the cylinder block side to the specified torque.
Tightening torque:25 N.m(2.5kg-m/18 lb-ft) NOTE:
· Do not hold the high pressure pipe of the pump instead of the handle when installing the supply pump.
· Make sure the O-ring is not protruding.

b. Confirm that the supply pump gear and the main gear (3) of the idle gear A are engaged. Push in the supply pump gear with the supplypump gear engaged with the sub gear(4) of the idle gear A

5. Install the timing chain and the supply pump sprocket.
a. Align the alignment mark (1) of the idle gear D and the blue plate(2) of the timing chain.
b. Align the alignment mark (3) of the supplypump sprocket and the yellow plate(4) of the timing chain.
c. Align the dowel pin of the supply pump gearand the notch of the supply pump sprocket, and install the supply pump sprocket.
d. Tighten the supply pump shaft nut with your hand.

8. Install the timing chain tensioner (2), gasket(3).
and oll feed pipe (1) and tighten at the specified torque.
Timing chain tensioner Tightening torque:
10N-m(1.0kg-m/87 lb-ft)
Oil feed pipe Tightening torque:
15N.m(1.5kg-m/11 lbt)

9. Remove the hook of the tensioner.
· Lightly push the area indicated with an arrow in the diagram.
The hook of the tensioner is removed, the plunger pushes the tension lever, and the chain is pulled.

10 tghten the supply pump shaft nut(1) at the specified torque.
Tightening torque:130 N-m(13.3kgm/96 b-t)

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11. Tighten the timing chain lever pivot at the specified torque.
Tightening torque:27 N-m(2.8 kg-m/20 lb-t)
12. Turm the crankshaft pulley 720°(two revolutions)
to make the tension in the chain even.
13. Align the alignment mark(1) of the camshaft bearing cap and the camshaft.

14. Install the cylinder head cover.
Refer to "Cylinder Head Cover"in Section 1B, Engine Mechanical.
15. Apply liquid gasket(TB-1207C or equivalent) to upper timing chain cover(1).
· After applying the liquid gasket, install the cover within five minutes.

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Legend
1. Lower chain cover
2. Bolt
3. Nut
19. Connect the camshaft position sensor connector
(1) and the engine coolant temperature sensor connector(2).
· Fasten the engine coolant temperature sensor connector harness to the connector with a clip
(3).

LNWA18SH30400120. Connect the fuel temperature sensor harness connector(1) and suction control valve harness connector(2).

21. Install the common rail.
Refer to "Common Rail"in this Section,
22. Install the A/C compressor bracket, and tighten at the specified torque.
Tightening torque:25N-m (2.5kg-m/18 lb-ft)
23. Install the A/C compressor adjust pulley, and tighten at the specified torque.
Bolt tightening torque:25N.m(2.5kg-m/18 lb-ft) Nut tightening torque:25 N-m(2.5kg-m/18 Ib-ft)

24. Install the A/C compressor.
· Install the A/C compressor, and tighten at the specified torque.
Tghtening torque:25 N-m(2.5kg-m/18 Ib-ft)
· Install the drive belt and adjust its tension using the adjust bolt of the tension pulley.
· Refer to "Drive Belt"in Section 1C, Engine Cooling
25. Install the engine oil level gauge guide tube, and tighten it at the specified torque.
Tightening torque:25 N,m(2.5kg-m/18 lb-A)
26. Install the left side fan guide bracket.
Refer to "Water Pump"in Section 1C, Engine Cooling.
27. Install the engine cover.
Tghtening torque:25 N-m(2.5 kg-m/18 lb-t)
28. Install the left side noise cover.
29. Install the dropping register harness connector.
30. Install the air cleaner outlet duct.
31. Install the radiator upper hose.
· Tighten radiator hose clip.
Tightening torque:5 N-m(0.5kgm/43 lb-in)32. Install the air intake duct and hose.
NOTE: Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.

· Install the duct and hose between the intake throttle valve and intercooler.
· Use a new hose clamp, align it with the marking.
Tghtening torque:8 N.m(0.8 kg-m/69 lbin)

33. Connect the connector of the boost sensor.
34. Refl the coolant.
Supply Pump Relearn
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Command the Fuel Supply Pump Learn Reseting with the scan tool.
4. Observe the Fuel Supply Pump Status Parameter with the scan tool. Confirm the scan tool indicates Not Learned.
5. Start the engine and let idle until engine coolant temperature reads 20℃ (68F) or higher while observing the Fuel Supply Pump Status parameter with a scan tool. The scan tool parameter changes status Not Learned>Learned.

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