FUEL SYSTEM 6C – 1

SECTION 6C
FUEL SYSTEM

TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 3
General Description....................................................................................................... 6C - 4
Fuel Flow.................................................................................................................... 6C - 4
Fuel Filter and Water Separator ............................................................................... 6C - 5
Injection Pump........................................................................................................... 6C - 7
Injection Nozzle ......................................................................................................... 6C - 8
Fuel Tank ........................................................................................................................ 6C - 9
Removal ..................................................................................................................... 6C - 9
Installation ................................................................................................................. 6C - 10
Fuel Pump ...................................................................................................................... 6C - 12
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Fuel Tube / Quick - Connector Fittings........................................................................ 6C - 14
Filler Neck ...................................................................................................................... 6C - 16
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Fuel Filler Cap ................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21
6C – 2 FUEL SYSTEM

PAGE
Injection Nozzle.............................................................................................................. 6C - 25
Inspection................................................................................................................... 6C - 25
Special Tools.................................................................................................................. 6C - 36
 FUEL SYSTEM 6C – 3

MAIN DATA AND SPECIFICATIONS

Description
Item
4JA1T (L) 4JA1TC 4JH1TC
Injection pump type Bosch distributor Bosch distributor VP44 type
VE type
Governor type Mechanical variable Electrical controled
(Half speed oil
pressure)
Timer type Oil pressure Electrical controled
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Number of injection nozzle orifices 5
Injection nozzle orifices
Inside diameter mm (in) 0.19 (0.0075) 0.17 (0.0067) 0.21 (0.0083)
Injection nozzle designed operating 19.1 (195) 19.0 (194) 19.5 (199)
2
pressure MPa (kg/cm ) 1st
25.0 (255) 33.5 (328) 33.8 (331)
2nd
Main fuel filter type Disposable cartridge paper element

Precautions
When working on the fuel system, there are several things
to keep in mind:
• Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
• Always keep a dry chemical (Class B) fire
extinguisher near the work area.
• Replace all pipes with the same pipe and fittings that
were removed.
• Clean and inspect “O" rings. Replace if required.
• Always relieve the line pressure before servicing any
fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
• Adhere to all Notices and Cautions.

NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.
6C – 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW

RTW46CMF000201

The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.
 FUEL SYSTEM 6C – 5

FUEL FILTER AND WATER SEPARATOR

As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The
fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches
the injection pump.
The water separator has an internal float. When the float reaches the specified level, a warning light comes on to
remind you to drain the water from the water separator.
A diaphragm type priming pump is installed at the top of the fuel filter. It is used during the air bleeding procedures.

(Except EURO III model)

RTW36CLF000701
6C – 6 FUEL SYSTEM

For EURO III model

RTW46AMF000201
 FUEL SYSTEM 6C – 7
INJECTION PUMP

RTW46CLF000201

4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engine’s vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.

4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.
6C – 8 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)

RTW46CMF000301

NOTE:
· Injection nozzle adjustment is possible only on the 4JA1L engine.

A hole (with 5 orifices) type injection nozzle. It consists of the nozzle body and the needle valve assembly.
The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion chamber through
the nozzle body injection orifice.
 FUEL SYSTEM 6C – 9
FUEL TANK
Fuel Tank and Associated Parts

RTW46CLF000401

Legend
1. Bolt; Fuel Tank
2. Fuel Tank Band
3. Fuel Tube/Quick Connector
4. Fuel Filler Hose
5. Fuel Tank
6. Under Shield Band
7. Under Shield (only, specified model)
8. Evapo Pipe (only specified model)
6C – 10 FUEL SYSTEM
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change
the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dust
entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house at rear left side.
6. Remove fixing bolt of the filler neck from the body.
7. Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering
and fuel leakage.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9. Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, don’t scratch
each hose and tube by around other parts.

Installation
1. Raise the fuel tank.
NOTE: When raise the fuel tank to the vehicle, don’t scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump
and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected against
stopper.
3. Install the tank band and fasten bolt.
Torque N·m (kg·m / lb ft)
68 (6.9 / 50)

NOTE: The anchor of the tank band must be certainly installed

to guide hole on frame.
4. Connect the quick connector of the fuel tube to the fuel pipe
and the evapo tube from evapo joint connector.
NOTE: Pull off the left checker on the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
 FUEL SYSTEM 6C – 11
5. Install the filler neck to the body with bolt.
6. Install the inner liner of the wheel house at rear left side.
7. Remove lifter from the fuel tank.
8. Lower the vehicle.
9. Tigten the filler cap until at least three clicks.
10.Connect the battery ground cable.
6C – 12 FUEL SYSTEM
FUEL GAUGE UNIT
Fuel Gauge Unit and Associated Parts

RTW46CLF000501

Legend
1. Fuel Feed Port 6. Fuel Tube/Quick Connector
2. Fuel Return Port 7. Retainer Ring (Fuel Gauge Unit Lock)
3. Fuel Emission Port 8. Seal; Fuel Gauge Unit
4. Fuel Gauge Unit and Sender Assembly 9. Fuel Tank Assembly
5. Connector; Fuel Gauge Unit 10. Evapo Tube/Quick Connector
 FUEL SYSTEM 6C – 13
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to “Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel
gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from
fuel gauge unit.
3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4. Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5. Discard fuel gauge unit seal (8) because it cannot be
reusable.

140R100035

Installation
1. Clean the seal surface of the fuel tank and the fuel gauge
unit.
NOTE: If there is dust on the seal surface, it becomes cause of
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel
tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no
bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from
fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
6C – 14 FUEL SYSTEM
8. Check leak.
Methed of leak check.
(1) Plug end of quick connector and breather hose (Pull off
the breather hose from fuel tank) and tighten fuel filler
cap until at least one click are heard.
(2) Apply water soap around the fuel gauge unit seal area.
(3) Pressure air into the fuel tank from end of breather pipe
2
at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds.
(4) Verify no bubbles around the fuel gauge unit seal area.
9. Install the fuel tank assembly (9).
NOTE: Refer to “Install the fuel tank” in this section.
 FUEL SYSTEM 6C – 15
FUEL TUBE / QUICK – CONNECTOR FITTINGS

Precautions
· Do not light a match or create a flame.
· Keep flames away from your work area to prevent
flammable materials from catching fire.
· Disconnect battery ground cable to prevent electrical shorts.
· Pre-treat piping system or associated parts from thermal
damage or from spattering when welding or similar
heat-generating work.

Cautions During Work

Do not expose the assembly to battery electrolyte or do not
wipe the assembly with a cloth used to wipe off spilt battery
electrolyte.
Piping that has been splattered with battery electrolyte or
battery electrolyte soaked cloth that was wiped on the piping
cannot be used.

140R100032

Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube

Removal
1. Open the fuel cap to relieve the fuel pressure in the tank.
Use compressed air to remove any dirt on the fuel quick
connect fittings prior to disconnecting the fittings.
When disconnecting the fuel pipe, cover the area with a
cloth to prevent fuel from splashing as the fuel pipe may
still have some pressure in it.

141R100002
6C – 16 FUEL SYSTEM
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.

140R100037

Cover the connectors that was removed with a plastic bag,

to prevent dust or rain water from entering.

140R100028

Reuse of Quick–Connector
· Replace the port and connector if scratch, dent or crack is
found.
· Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms of
rust, dent, scratch.
· After cleaning the port, insert it straight into the connector
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.
140R100036

Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface – which may decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.
 FUEL SYSTEM 6C – 17
FILLER NECK
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck assembly
is restored.
· Each joint area of the hose (to restore axial direction and
insertion length of the hose)
· Each fasten area of the clamp (to restore axial direction
and position of the clamp)
· Each bolt in the clamp (to restore fasten length of bolt in
the clamp)
· The band clip (to restore position and fasten length of
the band clip)
NOTE: Cover end of each hose and pipe to prevent any dust
entering.

Installation
1. Align each marking and restore the following point.
· Each joint area of the hose (Restore axial direction and
insertion length of the hose)
· Each fasten area of the clamp (Restore axial direction
and position of the clamp)
· Each bolt in the clamp (Restore fasten length of bolt in
the clamp)
Torque N·m (kg·m / lb ft)
2.5 (0.25 / 21.7)

filler neck side except flat deck model.

· The band clip (Restore position and fasten length of the
band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
6C – 18 FUEL SYSTEM
FUEL FILLER CAP

General Description
A vacuum valve and pressure valve are built into the fuel filler
cap which adjusts the fuel pressure in the fuel tank to prevent
fuel tank damage.

RTW36CSH000401

Legend
(1) Pressure Valve
(2) Vacuum Valve
(3) Seal Ring

Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective

CAUTION: A replacement fuel filler cap must be the same

as the original. The fuel filler cap valve was designed
primarily for this application and must be replaced with
the same type or decreased engine performance may
occur.
 FUEL SYSTEM 6C – 19
INJECTION PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.

Removal
1. Battery
Remove the battery from the battery tray.

6C-1

2. Drive Belt
1) Loosen the adjust bolt of the power steering pump
pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly

4. Accelerator Control Cable

Disconnect the accelerator cable from the intake throttle.

P1010003

5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the
intake throttle.
6. Fan
6C – 20 FUEL SYSTEM
7. Power Steering Pump Bracket

6C-4

8. Throttle Position Sensor Harness Connector

(4JA1TC/4JH1TC only)
Disconnect the harness connector from the throttle
position sensor.
9. Oil Level Gauge
10. Fuel Pipe
1) Disconnect the fuel hoses from the fuel filter or priming
pump.
2) Disconnect the fuel hoses from the injection pump.
11. Fuel Filter Assembly (Except EURO III model)

6C-5

12. Fuel Filter Bracket (Except EURO III model)

13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery
valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.

16. Intake Manifold

1) Remove the EGR valve from the intake manifold and
EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
17. Injection Pump Cover (4JA1TC/4JH1TC only)
 FUEL SYSTEM 6C – 21
18. Timing Check Hole Cover
1) Remove the timing check hole cover.
2) For ease in reinstalling the injection pump, align the
timing mark on the timing gear case cover by turning
the crankshaft using wrench.
And bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.
Note:
020L200017 If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.

RTW46CSH000201

3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear “B” fixing hole to prevent the scissors gear from
turning.

6C-7

29. Injection Pump Bracket

20. Injection Pump
6C – 22 FUEL SYSTEM
Installation


1. Injection Pump
1) Install the injection pump gear (When gear is
removed).
Injection Pump Gear Nut N×m (kg×m/lb ft)
64 (6.5 / 47)
2) Bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
RTW46CSH000201 crankshaft pulley TDC line aligned with the timing
mark.
3) Install the injection pump to the timing gear case with
align the timing mark on the pump gear to the arrow
mark on the timing gear case cover.
4) Check that the setting marks of the injection pump
gear and the idler gear B are aligned.
5) Remove the lock bolt (M6 ´ 30) from the idle gear “B”.

020L200017

6) Tighten the injection pump fixing bolts to the specified

torque.
Injection Pump Bolts Torque N·m (kg·m/lb ft)
19 (1.9 / 14)

6C-7
 FUEL SYSTEM 6C – 23
4JA1T (L)

RTW46CSH000101

4JA1TC/4JH1TC 2. Injection Pump Bracket

1) Install the injection pump bracket (6) and the bracket
bolts (7) and (8) to the cylinder body. Temporarily
tighten the bracket bolts.
2) Tighten the bracket bolts (7) to the specified torque.
3) Tighten the bracket bolts (8) to the specified torque.
Note:
Tighten the bracket bolt (8) first.
Injection Pump Bracket Torque N·m(kg·m / lb ft)
(8) 19 (1.9 / 14)

(7) 40 (4.1 / 30)

RTW36AMH000101

3. Timing Check Hole Cover

Install the timing check hole cover and tighten bolts to the
specified torque.
Timing Check Hole Cover Bolts
Torque N·m(kg·m / lb ft)
8 (0.8 / 69)

4. Injection Pump Cover (4JA1TC/4JH1TC only)

5. Intake Manifold
1) Install the intake manifold with gasket.
Intake Manifold Bolts
Torque N·m(kg·m / lb ft)
19 (1.9 / 14)

Intake Manifold Nuts Torque N·m(kg·m / lb ft)

24 (2.4 / 17)

2) Install the EGR valve to the intake manifold and EGR

pipe temporarily.
3) Tighten the nuts and bolts to the specified torque
Torque N×m (kg×m/lb ft)
Nuts 24 (2.4/17)
Bolts 27 (2.8/20)
6C – 24 FUEL SYSTEM
6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque N·m(kg·m / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
40 (4.1 / 30)

7. Injection Pipe Clip

Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.
Injection Pipe Clip Torque N·m(kg·m / lb in)
8 (0.8 / 69)

8. Leak Off Pipe and Leak Off Hose

Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.
9. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque N·m(kg·m / lb ft)
21 (2.1 / 15)

10. Fuel Filter Assembly (Except EURO III model)

Install the fuel filter assembly to bracket and tighten bolts
to the specified torque.
Fuel Filter Assembly Bolts
Torque N·m(kg·m / lb ft)
21 (2.1 / 15)

11. Fuel Pipe

1) Connect the fuel hoses to the fuel filter or priming
pump.
2) Connect the fuel hoses to the injection pump.
12. Oil Level Gauge
Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque N·m(kg·m / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)
 FUEL SYSTEM 6C – 25
13. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket
15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.

Euro under Euro I Euro II Euro III

4JA1L without with with Not used
With cooler
4JA1TC Not used Not used Not used (EGR cooler)
With
4JH1TC without with with (EGR cooler)

17. Accelerator Control Cable

1) Connect the accelerator cable to the injection pump
(4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery
6C – 26 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)
DISASSEMBLY

080L200009

Disassembly Steps
1. Retaining nut 9. Collar
2. Nozzle & pin 10. Spring seat
3. Spacer & pin 11. First spring
4. Lift Piece 12. Shim (First nozzle opening
pressure adjustment)
5. Spring seat 13. Nozzle holder body
6. Push rod 14. Eye bolt
7. Shim (Second nozzle opening 15. Gasket
pressure adjustment)
8. Second spring

Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.
 FUEL SYSTEM 6C – 27
REASSEMBLY

080L200010

Reassembly Steps
1. Nozzle holder body 9. Spring seat
2. Shim (First opening pressure 10. Lift Piece
adjustment)
3. First spring 11. Spacer & pin
4. Spring seat 12. Nozzle & pin
5. Collar 13. Retaining nut
6. Second spring 14. Gasket
7. Push rod 15. Eye bolt
8. Shim (Second opening pressure
adjustment)

Important Operations
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.
6C – 28 FUEL SYSTEM
REASSEMBLY AND ADJUSTMENT PROCEDURE
1 Adjust the first nozzle opening pressure using the shim.
First nozzle opening pressure adjustment

2 Confirm the full needle valve lift in accordance with the

Full needle valve lift confirmation
closed method.

3 Confirm pre-lift in accordance with the closed method.

Pre-lift confirmation
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.

4 Second nozzle opening pressure Confirm the second nozzle opening pressure in accordance
confirmation with the closed method.

5 Second nozzle opening pressure Adjust the second nozzle opening pressure using the shim.
adjustment

6 Confirm the condition of the fuel spray with the nozzle and
Final inspection nozzle holder assembled.

First nozzle opening pressure adjustment

Nozzle needle valve full-lift 0.25 mm (0.0098 in)
2
Nozzle needle valve pre-lift 0.04 mm(0.0016 in) at 20,000 kpa (2901 psi, 204 kg/cm )
Nozzle pressure
2
4JA1T(L) 1st Stage 19.1 Mpa (2759 psi, 194 kg/cm )
2
2nd Stage 25.5-27.0 Mpa (3768-3911 psi, 260-275 kg/cm )

NOTE: Only 4JA1L can perform adjustment of a nozzle.

 FUEL SYSTEM 6C – 29
Injection Nozzle Adjustment
First nozzle opening pressure adjustment
1.Clamp the nozzle holder in a vise.

040MV015.tif

2. Install the shim, first spring and spring seat in the

nozzle holder.

040MV016.tif

3. Install the collar, second spring, shim, spring seat and

pushrod in the nozzle holder.

040MV017.tif

4. Install the pins, lift piece and spacer in the nozzle

holder.

040MV018.tif
6C – 30 FUEL SYSTEM
5. Install the pins in the spacer.
6. Install the nozzle on the spacer.

040MV019.tif

7. Hand-tighten the adjustment retaining nut together

with the gasket to the nozzle holder.
Retaining nut: 157892-3200 (Bosch AS)
Gasket: 157892-5100 (Bosch AS)
(Bosch AS = Bosch Automotive Systems Corporation)

040MV010.tif

8. Tighten the adjustment retaining nut to the specified

torque.
Torque: 5.1 kg·m (36.9 Ib·ft/50 N·m)

040MV014-1.tif

9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.

CAUTION:
• Use a micrometer to measure shim thickness.

040MV030.tif
 FUEL SYSTEM 6C – 31
• First nozzle opening pressure adjusting shims
Parts No. (ISUZU) Thickness (mm)
115349-0420 0.40
115349-0430 0.50
115349-0440 0.52
115349-0450 0.54
115349-0460 0.56
040LX010.tif
115349-0470 0.58
115349-0480 0.60
115349-0490 0.70

Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining
nut.
Gasket: 026508-1140 (Bosch AS)
894227-6020 (ISUZU)
Plug: 157892-1600 (Bosch AS)

040MV013.tif

2. Position the nozzle holder with the nozzle facing down

and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 157892-5000 (Bosch AS)

040MV012.tif

3. Install the nut on the dial gauge holder.

Nut: 157892-1000 (Bosch AS)

040MV011.tif
6C – 32 FUEL SYSTEM
4. Install the pin to the dial gauge.

Note:
The lengths of the pins do not include the
threaded portions.
Pin (L=100 mm): 157892-5200 (Bosch AS)
Dial gauge: 157954-3800 (Bosch AS)
185317-0150 (ISUZU)

040MV029.tif

5. Secure the dial gauge to the nozzle holder using the

nut so that the pin contacts the tip of the first spring
seat.

CAUTION:
• Secure the dial gauge so that a stroke of 2 mm can
be measured.
• Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)

040MV009.tif

6. Set the nozzle holder to the nozzle tester and put

needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.

040MV030.tif
 FUEL SYSTEM 6C – 33
8. Operate the nozzle tester and increase the in-line
2
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that
the nozzle’s needle valve moves through its full lift.
Record full lift ‘L’. (Read dial gauge)
Nozzle Full Lift mm (in)
0.25 H 0.02 (0.0098 H 0.00008)

Note:
The above operation is used to determine whether
040MV008.tif
the nozzle seat is worn and whether the nozzle
assembly is in good condition.

Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.

Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.

040MV007.tif

040R300008
6C – 34 FUEL SYSTEM
2. Read the needle valve “pre-lift” point from the dial
gauge indication (once the needle valve has
descended when the second spring has stopped
operating).
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure +approx
2
1 MPa (10 kg/cm ).
Pre-lift mm
Pressure Mpa
2
(psi/ kg/cm ) Lift mm (in)
040H100007
4JA1T(L) 20.1 (2,858/205) 0.04 (0.0016)

Note:
This point can be found while the pressure is
decreasing.

3. Confirm that pre-lift is as specified.

040MV005.tif

4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit.
Service kit
105017-2990 (Bosch AS)
897302-3070 (ISUZU)

040MV031.tif

Second nozzle opening pressure confirmation

1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
2
kg/cm ) so that the nozzle’s needle valve moves
through its full lift.

040MV030.tif
 FUEL SYSTEM 6C – 35
2. Release the nozzle tester handle so that in-line
pressure decreases.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.

040MV022.tif

3. Then, read the pressure gauge indication (second

nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift (usually
pre-lift + 0.05 mm).
Second Nozzle Opening Pressure

Pressure Mpa
2 Lift mm (in)
(psi/ kg/cm )
4JA1T(L) 25.5-27.0 0.09 (0.0035)
(3768-3911/260-275)
040M100006
6C – 36 FUEL SYSTEM
Second nozzle opening pressure adjustment
If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and
replace the shim until the pressure is as specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
• Use a micrometer to measure shim thickness.
040MV017.tif • Use some combination of 3 adjusting shims to
adjust the pressure.

• Second nozzle opening pressure adjusting shims

Part No. Thickness Part No. Thickness
(ISUZU) (mm) (ISUZU) (mm)
897116-0290 0.10 897116-0380 0.53
897116-0320 0.20 897116-0390 0.54
897116-0330 0.30 897116-0400 0.55
897116-0340 0.40 897116-0410 0.56
897116-0350 0.50 897116-0420 0.57
897116-0360 0.51 897116-0430 0.58
897116-0370 0.52 897116-0440 0.59
040LX009.tif

Final inspection
1. Remove the dial gauge, nut and dial gauge holder.

040MV028.tif

2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-tighten
the retaining nut. Then, tighten the original retaining
nut to the specified torque.
Torque: 7.0 kg·m (50.6 Ib·ft/69 N·m)

040MV014-1.tif
 FUEL SYSTEM 6C – 37
4. Set the nozzle holder to the nozzle tester and check
first nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.

040MV030.tif
6C – 38 FUEL SYSTEM
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME

5-8840-2602-0
Remover: fuel pump retainer ring
(J-39765)