How to Install Injector for ISUZU F Series 4HK1 Euro 4

This instruction show you guide on how to install injector for ISUZU F series 4HK1 Euro 4 Engine 1C fuel system.

 

Preparations:

2023 2019 Isuzu G-IDSS Export Diagnostic Software Free Download

 

Procedures:

Component Views

Part name

1Bolt

2Injector terminal

3Nut

4Harness bracket

5Sound insulation cover

6Bolt

7Cylinder head cover

8Bolt

9Bolt

10EGR cooler duct

11 Bolt

12 Bolt

13 Gasket

14 EGR valve

15 Bolt

16 Injection pipe clip

17 Injection pipe

18 Sleeve nut

19 Injector clamp

20 Injector clamp bolt

21 Injector

22 Eyebolt

23 Injector leak-off pipe

24 Eyebolt

 

Tightening torque

1: 48 N・m { 4.9 kgf・m / 35 lb・ft }

3: 2.0 N・m { 0.2 kgf・m / 18 lb・in }

6: 8 N・m { 0.8 kgf・m / 6 lb・ft }

8: 18 N・m { 1.8 kgf・m / 13 lb・ft }

9: 28 N・m { 2.9 kgf・m / 21 lb・ft }

11: 24 N・m { 2.4 kgf・m / 18 lb・ft }

12: 104 N・m { 10.6 kgf・m / 77 lb・ft }

15: 24 N・m { 2.4 kgf・m / 18 lb・ft }

16: 8 N・m { 0.8 kgf・m / 71 lb・in }

17: 25 N・m { 2.5 kgf・m / 18 lb・ft }

18: 30 N・m { 3.1 kgf・m / 22 lb・ft }

20: 30 N・m { 3.1 kgf・m / 22 lb・ft }

22: 15 N・m { 1.5 kgf・m / 11 lb・ft }

24: 27 N・m { 2.8 kgf・m / 20 lb・ft }

 

Injector Installation

1) Install the O-ring to the injector.

2) Install the injector gasket to the injector.

3) Install the injector and injector clamp to the cylinder head.

4) Apply molybdenum disulfide grease to the injector clamp tightening bolt.

5) Temporarily tighten the injector clamp tightening bolt to the cylinder head.

When replacing the injector

1) Erase the old cylinder number ID code on the Injector ID Code label using a black pen, etc.

Note:

• The Injector ID Code label is attached to the sound insulation cover.

Label on the cylinder head cover (SAMPLE)

2) Record the 24-digit Injector ID Code of the new injector.

Note:

• The Injector ID Code is marked on the injector ID plate.
• The Injector ID Code in the diagram should be read as 64 DA A5 05 2F 4C 0F 36 FA 17 25 8C.

 

Injection Pipe Installation

1) Lightly apply engine oil to the outer circumference of the injector side sleeve nuts on the injection pipe.

2) Temporarily tighten the injection pipe lightly with an open-end wrench until it attaches securely to the common rail (fuel rail) and injector.

Caution:

• Do not reuse the injection pipe.

3) Install the injection pipe clip to the injection pipe.

Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }

4) Final tighten the injector clamp tightening bolt to the cylinder head.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

5) Securely tighten the injection pipe to the common rail (fuel rail).

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6) Securely tighten the injection pipe to the injector.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

 

Injector Leak-Off Pipe Installation

1) Install the injector leak-off pipe to the injector and cylinder head.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft } Cylinder head side

Tightening torque: 15 N・m { 1.5 kgf・m / 11 lb・ft } Injector side

 

Injector Harness Installation

1) Install the harness bracket and injector harness as a set to the cylinder head.

Tightening torque: 48 N・m { 4.9 kgf・m / 35 lb・ft }

2) Connect the connector to the lower cover.

3) Install the injector terminal nut to the injector.

 

Caution:

• Uniformly tighten the nuts by alternately tightening the nuts separately 2 to 3 times.
• Do not over-tighten the injector terminal nut as it will break the terminal stud.

 

Tightening torque: 2.0 N・m { 0.2 kgf・m / 18 lb・in }

Install cylinder head cover

ECM Setting

Note:

• If the injector is replaced, perform the Injector ID Code programming.

1.Injector ID Code programming

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

• Diagnostics > Engine > 4HK1-TC > Programming > Injector ID Code > Program Injector ID Code

4) Program the Injector ID Code into the ECM by following the on-screen instructions.

5) After the programming is completed, turn the ignition switch OFF for 30 seconds