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.

Isuzu G-IDSS Diagnostic Service System [03.2022]

Perkins 2806F Engine Fuel Manifold (ARD) Remove and Install

This paper mainly introduces how to Remove  and  Install Perkins 2806F Engine Fuel Manifold (ARD)

1. Turn the fuel supply to the OFF position.
2. Turn the battery disconnect switch to the OFF
position.

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3. Make temporary marks on harness assemblies (1).
Disconnect the harness assemblies from the
pressure sensors.
4. Cut cable straps (3) from the harness assemblies.
5. Disconnect harness assembly (2) and harness
assembly (4).
6. Disconnect the Original Equipment Manufacturer
(OEM) hose assembly (6). Remove O-ring seal (5)
(not shown)

7. Disconnect tube assembly (7) and tube assembly
(9).
8. Remove bolts (13) from Aftertreatment
Regeneration Device (ARD) fuel manifold (11) and
clip (12).
9. Remove ARD fuel manifold (11) from the bracket.
10. Remove O-ring seal (8) (not shown) and O-ring
seal (10) (not shown)

c. Remove adapter (23) from ARD fuel manifold
(11). Remove O-ring seal (22).
d. Remove adapter (20) and adapter (24) from
ARD fuel manifold (11). Remove O-ring seal
(21) and O-ring seal (25).
e. Remove nut (31) and washer (30).
f. Remove solenoid (29) from valve (28).
g. Use suitable tooling to remove valve (28) from
ARD fuel manifold (11).
h. Remove O-ring seal (26) and O-ring seal (27)
from valve (28).
i. Repeat Step 11.e through Step
11.h to remove
 the assembly of solenoid valve (19) from ARD
fuel manifold (11).
Installation Procedure
1. Ensure that all components of the ARD fuel
manifold are free from damage, wear, or
restriction.

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2. If necessary, follow Step 2.a through Step 2.h to
assemble ARD fuel manifold (11), install the
assembly of solenoid valve (18), and solenoid
valve (19).
a. Position ARD fuel manifold (11) in a suitable
support.
b. Install a new O-ring seal (21) and a new O-ring
seal (25) to adapter (20) and adapter (24).
Install the adapters to ARD fuel manifold (11).
Tighten the adapters to a torque of 17 N·m
(150 lb in)
c. Install a new O-ring seal (22) to adapter (23).
Install the adapter to ARD fuel manifold (11).
Tighten the adapter to a torque of 30 N·m
(266 lb in).
d. Install a new O-ring seal (26) and a new O-ring
seal (27) to valve (28) for the assembly of
solenoid valve (18).
e. Install valve (28) to ARD fuel manifold (11). Use
a deep socket to tighten the valve to a torque of
50 N·m (37 lb ft).
f. Install solenoid (29) to valve (28). Install washer
(30) and nut (31). Tighten the nut to a torque of
20 N·m (177 lb in).
g. Repeat Step 2.d through Step 2.f to install
remaining assembly of solenoid valve (19).
h. Install new O-ring seal (16) and new O-ring seal
(16) to pressure sensor (14) and pressure
sensor (15). Use a suitable deep socket to
install the pressure sensors to ARD fuel
manifold (11). Tighten the pressure sensors to a
torque of 28 N·m (248 lb in)

3. Install a new O-ring seal(8) (not shown) and a new
O-ring seal(10) (not shown) to the adapter on ARD
fuel manifold (11).
4. Install ARD fuel manifold (11) onto the bracket.
Install bolts (13) to clip (12) and the ARD fuel
manifold.
5. Connect tube assembly (7) and tube assembly (9)
to ARD fuel manifold (11). Tighten the tube nuts for
tube assemblies hand tight.
6. Tighten bolts (13) to a torque of 55 N·m (41 lb ft).
7. Tighten tube nuts for tube assembly (7) and tube
assembly (9) to a torque of 45 N·m (33 lb ft).
Ensure that the tube assemblies are not strained
as the tube nuts are tightened.

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8. Install a new O-ring seal (5) (not shown). Connect
the OEM hose assembly (6). Tighten the hose
assembly, refer to the OEM for the correct
tightening value.
9. Connect harness assembly (2) and harness
assembly (4). Install new cable straps (3) to the
harness assemblies.
Note: Ensure that the cable straps meet Original
Equipment Manufacturer (OEM) specifications.
10. Connect harness assemblies (1) to the pressure
sensors. Ensure that the harness assemblies are
connected in the original positions.
11. Turn the fuel supply to the ON position
12. Turn the battery disconnect switch to the ON
positio

Reinstallation of Doosan Pressure Control Sequence Valve

 This paper mainly introduces how to reinstall the doosan pressure control sequence valve

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1. Figure 16, shows PP plug and spool

2 Figure 17, shows outer spool and outer PP plug. Plug is
installed with spool.

3. Install spool into bore. See Figure 18. Use a nylon rod to
position spool in neutral position.

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4. Install spring and LS plug into bore. See Figure 19. Use a
new O-ring on plug

5. Use a 27 mm wrench to tighten PP plug and LS plug to 6
kg•m (44 ft lb). See Figure 20.

6. Assemble valve needle, spring and set screw into pressure
relief valve housing. See Figure 21. Thread pressure relief
valve into body of priority valve and tighten it. See Figure
21.





7. Install plug into pressure relief valve bore. Tighten plug to 5
kg•m (36 ft lb). See Figure 22.

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Doosan Steering Pressure Control Sequence Valve Setting

This article introduces the pressure control sequence valve setting of Doosan steering gear

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Theory of Operation Oil output from the steering pump flows through the priority valve to both the loader supply line and to the steering circuit. During operation of the steering wheel, the priority valve shifts and supplies pump flow only to the steering circuit. This results in smooth operation of the steering circuit.
At rest, the spool(1, Figure 4) maintains an open path between inlet port P and steering outlet port CF. Port EF is kept closed by the force from spring (2, Figure 4). The spool(1, Figure 4)
contains a drilled passage. The passage is open to port CF and is also open to both ends of the spool. At the neutral position of the steering unit, oil from port P flows through port CF and into the drilled passage in the spool. At this time, oil flowing out of CF is blocked at the control spool of the steering unit. This raises the pressure in port CF. At this time, port LS is open to the chamber on the far right side of the priority valve. Port LS is notopen to the chamber on the far left side of the valve. As oil flows through the drilled passage in the spool, pressure builds on the left side of the spool but pressure is low on the right side of the spool because oil can drain into port LS. When oil pressure on the left side of the spool rises above the force of spring (2, Figure 4), the spool(1, Figure 4) shifts the right. This allows pump flow at port P to flow out both ports CF and EF. Now both the loader supply line and the steering supply line are charged with flow from the steering pump. Whenever the steering wheel is turned, the spool in the steering unit directs some oil flow back to port LS. This equalizes the oil pressure on both ends of thespool(1, Figure 4). The spring now shifts the spool to the left.
This closes off the passage from port P to port EF. This makes all steering pump flow now available only to the steering circuit from port CF.

SPECIAL TOOLS
1. The following tools are necessary to repair the priority valve. See Figure 6.
Open end wrench-27mm Slip joint pliers Nylon rod Allen wrenches-5 mm,8 mm and 10mm

 

DISASSEMBLY
1.Use open end wrench to loosen PP plug.See Remove O-ring.

2.Use open end wrench to loosen LS plug.See Figure 8.
Remove O-ring.





3.Remove spring.See Figure 9.

4.Use a nylon rod to push spool out of bore.See Figure 10.

5.Use an 8 mm allen wrench to remove plug from pressure relief valve.See Figure 11

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6.Use a 10 mm allen wrench to unscrew pressure relief valve from its bore.See Figure

7.Hold pressure relief valve with a pliers and use a 5 mm allen wrench to remove set screw.See Figure 13.

8. The pressure relief valve is composed of a valve housing, valve needle, spring and set screw. See Figure 14.

CLEANING AND INSPECTION
(WEAR LIMITS AND TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures"section.
Clean all parts with a nonflammable, nontoxic solvent.
Carefully inspect all parts. Replace all worn or broken parts. Use only new O-rings to assemble the valve.
Cost all parts with oil before assembling them.

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Perkins EngineFuel Filter Base - Install

 This article describes the installation of the Perkins 2806F engine fuel filter base

Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the fuel filter base and bracket are free
from wear or damage. Replace any component
that is worn or damaged.
Illustration 14 g06079253
2. If necessary, follow Step 2.a through Step 2.h to
assemble and install bracket (12).
a. If necessary, follow Step 2.a through Step 2.d to
assemble bracket (12).
b. Install mount (19), mount (21), and limiter (18)
to bracket (12). Ensure that the mounts are
correctly orientated.
c. Install bolt (16) and washer (17). Ensure that the
washer is correctly orientated.
d. Install washer (20) and nut (22). Tighten the nut
and bolt (16) to a torque of 25 N·m (221 lb in).
e. Install washer (23) to bolt (16)

f. Repeat Step 2.b through Step 2.e to install
remaining washer (23), nut (22), washer (20),
bolt (16), mount (19), mount (21), and limiter
(18) from bracket (12).
g. Position bracket (12) onto the cylinder block.
Install bolt (14) and bolt (15).
Tighten bolt (14) to a torque of 214 N·m
(158 lb ft).
Tighten bolt (15) to a torque of 47 N·m
(35 lb ft).
h. Install bolt (13) to the tube assembly clip.
Tighten the bolt to a torque of 47 N·m (35 lb ft)
3. Install fuel filter base (3) to the bracket. Install nuts
(2) and tighten to a torque of 25 N·m (221 lb in).
4. Position bracket (7) onto fuel filter base (3). Install
nuts (8). Tighten the nuts to a torque of 25 N·m
(221 lb in).
5. Remove the plug from tube assembly and the cap
from connection on the fuel filter base. Install a
new O-ring seal (5) (not shown). Ensure that the
O-ring seal is correctly installed into the recess of
the adap6. Connect tube assembly (6) to fuel filter base (3).
Install nut (11) for clip on tube assembly. Tighten
the tube nut for the tube assembly to a torque of
60 N·m (44 lb ft).
Tighten the nuts to a torque of 25 N·m (221 lb in).
7. Remove the plug from the hose assembly and the
cap from connection on the fuel filter base.
Connect hose assembly (10) to fuel filter base (3).
Tighten the hose assembly to a torque of 60 N·m
(44 lb ft).
8. Connect the harness assembly to fuel temperature
sensor (1).
9. Connect the harness assembly to fuel pressure
sensor (4).
10. Install new fuel filters (9). Refer to Operation and
Maintenance Manual, “Fuel Filter - Replace” for
the correct procedure.
11. Turn the fuel supply to the ON position.
12. Remove the air from the fuel system. Refer to
Systems Operation, Testing and Adjusting, “Fuel
System - Prime” for the correct procedure.

Fuel Priming Pump - Remove

This article is about how to disassemble the fuel filter base

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Removal Procedure
1. Turn the fuel supply to the OFF position.
2. Turn the battery disconnect switch to the OFF
position.
3. For the correct location of the fuel priming pump
assembly. Refer to Original Equipment
Manufacturer (OEM) for the correct location.

4. Remove fuel filter (9). Refer to Operation and
Maintenance Manual, Fuel System Primary Filter
(Water Separator) Element - Replace for the
correct procedure.
5. Disconnect harness assembly (2), harness
assembly (3), and harness assembly (8).

6 M0070446
Disassembly and Assembly Section

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9. If necessary, follow Step 9.a through Step 9.j to
disassemble the assembly of fuel filter base (1).
a. Place the assembly of fuel filter base (1) in a
suitable support.
b. Remove nut (21) and remove solenoid (22).
c. Use a deep socket to remove valve (23).
Remove O-ring seal (24), O-ring seal (25), and
backing ring (26).
d. Remove check valve (35). Remove O-ring seal
(30), O-ring seal (29), and backing ring (28)
e. Remove bolts (27) from manifold (34). Remove
O-ring seal (33).
f. Remove O-ring seal (19) and backing ring (20).
g. Make temporary marks on wiring harness (37)
for installation purposes. Remove locking nuts
(32). Remove electronic filter (31) and
disconnect the wiring harness from pump
assembly (43).
h. Remove pump assembly (43) from fuel filter
base (1). Remove backing ring (40), seal (41),
backing ring (42), and seal (39).
i. If necessary, remove circlip (36) and remove
wiring harness (37) from fuel filter base (1).
6 M0070446
Disassembly and Assembly Section
Remove O-ring seals (38).
j. If necessary, remove plug (48) from fuel filter
base (1). Remove O-ring seal (47). Remove
spring (46), valve (45), and O-ring seal (44).
If necessary, repeat Step 9.j to remove
remaining valve assembly (49).
Installation Procedure
1. Ensure all the components of the fuel priming
pump assembly are free from wear, damage, and
restriction.
Illustration 5 g06096521
M0070446

Correct orientation of fuel priming pump (44).
Correct position of electronic filter (32)
Position (A) is the negative (-) terminal on fuel priming
pump (44)
Position (B) is the positive (+) terminal on fuel priming
pump (44)
2. If necessary, follow Step 2.a through Step 2.m to
assemble the assembly of fuel filter base (1).
Note: Use the pump seal installer that is provided
in the pump kit to press in the new pump and the
seals.
a. Place the assembly of fuel filter base (1) in a
suitable support.
b. If necessary, install new O-ring seals (38) to
wiring harness (37). Install the wiring harness to
fuel filter base (1). Ensure that the wiring
harness is correctly installed into the fuel filter
base. Install circlip (36) to the fuel filter base.
Ensure that the circlip is correctly installed into
the recess of the fuel filter base.
c. Install new seal (39), backing ring (42), seal
(41), backing ring (40) to pump assembly (43).
d. Install pump assembly (43) to fuel filter base (1).
Ensure that the pump assembly is installed
into the fuel filter base squarely, is correctly
seated, and is correctly orientated into the
fuel filter base. Refer to Illustration 7 for the
correct orientation.
e. Connect wiring harness (37) to pump assembly
(43). Ensure that the harness assembly is
correctly connected to the pump assembly.
Refer to Illustration 7 .
f. Install electronic filter (31) to pump assembly
(43). Refer to Illustration 7 . Install new locking
nuts (32). Tighten the locking nuts to a torque of
1.3 N·m (1 lb ft)
g. Install new O-ring seal (19) and backing ring
(20) to pump assembly (43). Ensure that the Oring seal and the backing ring are correctly
installed.
h. Install a new O-ring seal (33) to fuel filter base
(1). Install manifold (34). Install bolts (27).
Tighten the bolts to a torque of 12 N·m
(106 lb in).
i. Install new O-ring seal (24), O-ring seal (25),
and backing ring (26) to valve (23). Ensure that
the O-ring seal and the backing ring are
correctly positioned.
j. Use a deep socket to install valve (23). Tighten
the valve to a torque of 50 N·m (37 lb ft).
k. Install solenoid (22) to valve (23). Install nut
(21). Tighten the torque to 6.5 N·m (58 lb in)
l. Install new O-ring seal (30), O-ring seal (29),
and backing ring (28) to check valve (35). Install
the check valve to manifold (35). Tighten the
check valve to a torque of 34 N·m (301 lb in).
m. If necessary, install a new O-ring seal (47) to
plug (48). Install a new O-ring seal (44) onto
valve (45). Install the valve, spring (46), and the
plug to fuel filter base (1). Tighten the plug to a
torque of 90 N·m (66 lb ft).
If necessary, repeat Step 2.m to install
remaining valve assembly (50).

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3. If necessary, follow Step 3.a through Step 3.c to
install mounts (13), mounts (10), limiters (16),
limiter (11), and bracket (14) to fuel filter base (1).
a. Install mount (10), limiter (11) and mount (12) to
fuel priming pump (1).
b. Install limiters (16) and mounts (17) and mounts
(15) to fuel priming pump (1).
c. Install bracket (14) and mounts (13).
4. Position fuel priming pump base (1) onto the OEM
mounting point. Install bolts (6) and washers (5) to
the fuel priming pump base. Tighten the bolts to a
torque of 27 N·m (239 lb in).
5. Connect harness assembly (2), harness assembly
(3), and harness assembly (8).
6. Install a new fuel filter (9). Refer to Operation and
Maintenance Manual, Fuel System Primary Filter
(Water Separator) Element - Replace for the
correct procedure.
7. Turn the fuel supply to the ON position.
8. Turn the battery disconnect switch to the ON
position.
9. Remove plug and cap from the connections and
the hose assemblies. Connect the OEM hose
assemblies to the connections (4) Tighten the
hose assemblies, refer to the OEM for the correct
torque value.
10. Remove cap from connection (4a) and connect
the OEM hose assemble. Tighten the hose
assemblies, refer to the OEM for the correct torque
value.
11. Follow Step 11.a through Step 11.c to flush the
fuel pump and the hose assembly for the supplies
to the Aftertreatment Regeneration Device (ARD).
M0070446 9
Disassembly and Assembly Section
a. Disconnect the hose assembly from the ARD.
Use two people to flush the fuel pump and the
hose assembly for the supplies to the ARD into
a suitable container for disposal.
b. The fuel pump can be activated by turning on
the key or pressing the manual switch. The
manual switch, if available, the switch is on the
primary fuel filter base.
c. After the flushing procedure has been carried
out, connect the hose assembly to the ARD.
Tighten the hose assemblies, refer to the OEM
for the correct torque value.