Fuel System 6C-1

ENGINE
Fuel System
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .6C-2
A List of Defective Phenomena . . . . . . . . . . . . .6C-7
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-7
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . .6C-8
Fuel System Check . . . . . . . . . . . . . . . . . . . . . .6C-9
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . .6C-16
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-16
Fuel Filter Cartridge . . . . . . . . . . . . . . . . . . . . . .6C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-25
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-25
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-26
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-27
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-30
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-31
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-31
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-36
Fuel Sedimenter Switch . . . . . . . . . . . . . . . . . . .6C-37
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-40
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-40
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-41
Tightening Torque Specifications . . . . . . . . . . .6C-41
6C-2 Fuel System

Fuel System

Service Precautions Work Procedure

Parts of the fuel system such as the internal part of the • The fuel opening must be quickly sealed when
fuel injector, holes and clearances that form passages removing the fuel pipe, injection pipe, fuel injector,
for fuel are finished to a very high degree of accuracy. fuel supply pump, and fuel rail.
They are therefore highly sensitive to foreign matter • The eyebolts and gasket must be stored in a clean
and the entry of foreign matter could cause damage to parts box with a lid to prevent adhesion of foreign
the fuel passage. Therefore, effective measures should matter.
be taken to prevent the entry of foreign matter. • Fuel leakage could cause fires. Therefore, after
If water removal agent is used in the fuel then it will finishing the work, wipe off the fuel that has leaked
absorb moisture in the light oil and may cause rust. out and make sure there is no fuel leakage after
Therefore, do not use water removal agent in the fuel starting the engine.
tank.
Explanations on Functions and Operation
Fuel System Diagram

8
5

N6A6661E

Legend
1. Fuel Rail 7. Ventilation Hose
2. Leak-off Pipe 8. Fuel Filler Cap
3. Fuel Injector 9. Fuel Level Sensor
4. Fuel Return Pipe 10. Fuel Filter With Sedimenter
5. Fuel Feed Pipe 11. Fuel Supply Pump
6. Fuel Tank

Caution:
• Do not let foreign matter such as sand or dust get
into fuel.
• Use gas oil for fuel, not others.
 Fuel System 6C-3
Fuel Rail

N6A6358E

Legend
1. Flow Damper 3. Pressure Sensor
2. Pressure Limiter
6C-4 Fuel System
Fuel Supply Pump

N6A6359E

Legend
1. Fuel Temperature Sensor 4. Camshaft Key
2. Fuel Rail Pressure Regulator 5. Camshaft Nut
3. High Pressure Piping
 Fuel System 6C-5
Fuel Injector Fuel Filter

N6A6361E

Legend
1. Priming Pump
2. Cartridge
3. Sensor
4. Heater
5. Drain Plug

Functional check
N6A6360E
Air bleeding
Legend
1. Terminal Stud
2. Fuel Leak-off Port
3. O-ring
4. Fuel Inlet Port
5. Injector Parts Number Marking
6. Fuel Injector ID Plate

N6A6362E
N6A6362E

Legend
1. Priming Pump
2. Air Bleed Plug

1. Before starting the engine

a. Fit a tray below the fuel filter (below the air
bleed plug).
b. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
overflows from the plug hole.
6C-6 Fuel System
c. Tighten the plug, and operate the priming pump 2. Install the adapter.
more than 10 times until it is filled with fuel.
After waiting for approximately a minute, loosen Special tool
the plug and bleed off the air in the fuel filter. Fuel Pressure/Vacuum Gauge Set:
(This work must be repeated a minimum of 5-8840-2844-0
three times until no more air comes out from the (Fuel pressure/vacuum gauge adapter:
plug.) EN-47667)
d. Tighten the plug firmly and wipe the fuel in the 3. Connect the gauge (1) with hose to the adapter
surrounding area. Operate the priming pump (5).
(10 to 15 times) till it is filled with fuel and then
send fuel to the engine. Special tool
2. After starting the engine Fuel Pressure/Vacuum Gauge Set:
5-8840-2844-0
a. Start the engine by rotating the starter without
(Fuel pressure/vacuum gauge assembly:
depressing the accelerator pedal.
J-44638)
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly rotate the idling control knob clockwise
and maintain it for 3 minutes.
d. Fully depress the accelerator pedal and
increase the rotations to maximum. (Repeat
this operation several times)
e. Rotate the idling knob counterclockwise and
return to idling mode.

Caution:
If the air bleeding work is insufficient then it could lead
to faults in the engine. Therefore, the procedures after
starting the engine should always be implemented.

Water drain
A warning lamp will light up if water is collected more
than fixed quantity in the sedimenter. If the warning
lights up, drain out the water by following operations:
• Fit a tray below the fuel filter.
• Loosen the drain plug.
• Operate the priming pump several times to
discharge the water.
• Tighten the drain plug after discharging the water.
• Operate the priming pump several times and
check for fuel leakage.
N6A6363E
• Check that the warning lamp in the meter is off.
Legend
Fuel system vacuum check 1. Fuel Pressure/Vacuum Gauge Assembly
2. Fuel Pipe (Intake Side)
Use this procedure to measure the vacuum (negative 3. Fuel Pipe (Discharge Side)
pressure) discharge side the fuel system. 4. Fuel Filter
5. Fuel Pressure/Vacuum Gauge Adapter
Important:
The fuel pressure/vacuum gauge assembly (gauge (1)) 4. Loosen the air bleeding plug on the supply pump.
and the fuel pressure/vacuum gauge adapter (adapter
(5)) must be cleaned before connect to the fuel line. 5. Use your hand to operate the fuel filter priming
Otherwise, foreign material adherent to the tools may pump. Operate the pump until all the air has been
damage the fuel supply pump. bled from the system.
6. Start the engine and allow it to idle.
1. Disconnect the fuel hose from the fuel filter
housing. (fuel supply pump side).
 Fuel System 6C-7
7. Note the gauge (1) reading. If the reading is 8. Remove the gauge (1) and hose from the adapter
normal, go to Step 8. If the fuel vacuum is greater (5).
than the specified value, there is a problem in the 9. Remove the adapter (5).
fuel system. Perform the procedures outlined
10. Connect the fuel hose.
below.
11. Use your hand to operate the fuel filter priming
Standard fuel vacuum: Less than 5 inHg pump. Operate the pump until all the air has been
bled from the system.
• Replace the cartridge fuel filter element.
12. Start the engine and allow it to idle.
• Check the fuel delivery pipe. If it is clogged, it
must be replaced. 13. Inspect the fuel system for fuel leakage.
• Remove the fuel pipe at the fuel filter inlet. Use
high-pressure air forced through the fuel pipe to A List of Defective Phenomena
clean the fuel system.
• Problems with starting
Caution: • Hunting during idling
• Remove the fuel filler cap before applying high- • Insufficient horsepower
pressure air. • Maximum engine speed is too low
• Do not perform this procedure if the fuel tank is • Engine does not stop
nearly full (fuel approaching or flowing into the fuel
• Exhaust gas is blue or black.
filler neck). The forced air will spray fuel from the
fuel filler neck.
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2844-0
Fuel Pressure / Vacuum
Gauge Set
(J-44638 [Fuel Pressure /
Vacuum Gauge
Assembly]
EN-47667 [Suction Side
5884028440 Fuel Pressure / Vacuum
Gauge Adapter])
6C-8 Fuel System
Trouble Shooting
Problems with starting

Condition Possible Cause Correction

Problems with starting Fuel tank is empty Fill the tank.
Air has entered the fuel system. Bleed the air.
Fuel line is clogged or damaged. Repair or replace the fuel line.
Connection to the fuel line is loose. Re-tighten the connection.
Fuel filter element is clogged. Replace the cartridge.
Fault in the feed pump Replace the fuel supply pump.
Regulating valve is open. Replace.
Sticking of the fuel injector nozzle Replace the fuel injector.
Defective engine control system Diagnose the engine control
system.

Unstable idling

Condition Possible Cause Correction

Hunting during idling Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel Repair or replace the fuel system.
system
Water particles or foreign matter in Replace the fuel.
the fuel system.
Fuel filter element is clogged. Replace the fuel filter element
(cartridge).
Sticking of the fuel injector nozzle Replace the fuel injector.
Defective engine control system Diagnose the engine control
system.

Insufficient power

Condition Possible Cause Correction

Insufficient horsepower Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel Repair or replace the fuel system.
system
Water mixes in the fuel system Replace the fuel.
Fuel filter element is clogged. Replace the element or the
cartridge.
Sticking of the fuel injector nozzle Replace the fuel injector.
Defective engine control system Diagnose the engine control
system.

Maximum engine speed is too low

Condition Possible Cause Correction

Maximum engine speed is too low Fuel line is clogged or damaged. Repair or replace the fuel line.
Defective engine control system Diagnose the engine control
system.
 Fuel System 6C-9
Engine does not stop

Condition Possible Cause Correction

Engine does not stop Defective engine control system Diagnose the engine control
system.

Exhaust gas is blue or black

Condition Possible Cause Correction

Exhaust gas is blue or black. Reduction in injection-valve Replace the fuel injector.
opening pressure or defective
atomizing status
Engine control system malfunction System diagnosis.

Fuel System Check • The batteries are completely charged.

Description • The engine cranking speed is normal.
The common rail fuel system is comprised of two fuel • There is adequate fuel in the fuel tank.
Pressure sections: a suction side between the fuel tank • There is no air in the fuel line.
and the fuel supply pump and a high-pressure side
between the fuel supply pump and the fuel injectors. Diagnostic Aids
Fuel is drawn from the fuel tank via a feed pump and • The fuel system from the fuel tank(s) to the fuel
then pumped into the fuel rail by two plungers, all of supply pump is under a slight vacuum with the
which are internal to the fuel supply pump. This high engine running. As a result, air can enter the fuel
pressure is regulated by the engine control module system if these connections are not tight or if there
(ECM) using the fuel rail pressure (FRP) regulator is a crack in one of the fuel hoses. Air in the fuel
dependant upon values from the FRP sensor attached system will cause fuel rail pressure fluctuations
to the fuel rail. In case of fuel rail overpressure, a especially at high engine speed and load.
pressure limiter valve threaded into the fuel rail will
• If the fuel tank is empty or near empty, air might be
open to release overpressure and return fuel back to
allowed to go into the fuel system. With air in the
the fuel tank.
fuel system, smooth flow of fuel into the supply
The Fuel System Check diagnostic table directs the
pump is interrupted. Perform bleeding of fuel
service technician to the appropriate fuel system
system after refilling.
diagnosis. The diagnostic table assumes the following
conditions are met:

Step Action Value(s) Yes No

1. Install the Tech 2.
2. Turn OFF the ignition for 30 seconds.
3. Turn ON the ignition, with the engine
OFF.
1 —
4. Observe the Diagnostic Trouble Code
(DTC) Information of the engine control Refer to
module with a Tech 2. Applicable DTC in
Engine Control
Are any DTC(s) set? Section Go to Step 2
6C-10 Fuel System

Step Action Value(s) Yes No

1. Inspect the high pressure side between
the fuel supply pump and the fuel
injectors for fuel leakage. The following
components may contain an external
leak:
• Fuel supply pump
• Fuel rail
• Pressure limiter valve
• Flow damper valve
• Fuel rail pressure (FRP) sensor
• Fuel pipe between the fuel supply
pump and fuel rail
2 —
• Fuel pipe between the fuel rail and
fuel injectors
• Each fuel pipe sleeve nuts

Notice:
Fuel may leak under the cylinder head cover
from the inlet high pressure line. In such case,
the engine oil level will rise. Inspect for fuel in
the engine oil.

2. Repair any fuel system leaks as

necessary.

Did you find and correct the condition? Go to Step 18 Go to Step 3

1. Turn OFF the ignition.
2. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper
clamps.

Notice:
The fuel system from the fuel tank(s) to the
fuel supply pump is under a slight vacuum
with the engine running. As a result, air can
enter the fuel system if these connections are
not tight. Air in the fuel system will cause fuel
3 rail pressure fluctuations especially at high —
engine speed and load.

3. Pump the priming pump on the fuel filter

until it becomes firm .If there is a leak on
the suction side of the fuel system
between the priming pump and the fuel
supply pump, the priming pump will not
build up sufficient firmness and fuel
leakage may occur.
4. Repair any fuel system leaks as
necessary.
Did you find and correct the condition? Go to Step 18 Go to Step 4
 Fuel System 6C-11

Step Action Value(s) Yes No

1. Make sure the fuel tank(s) have adequate
fuel and the fuel quality is good (take a
sample).
2. Bleed the air from the fuel system as
necessary. Refer to Fuel System Air
Bleeding in this section.
3. Start the engine and let idle. If the engine ±5MPa
4 does not start, continue to crank. ±(725 psi)
4. Observe the Differential Fuel Rail
Pressure parameter with the Tech 2 while
cranking over the engine or running the
engine.

Is the Differential Fuel Rail Pressure

parameter within the specified value? System OK Go to Step 5
1. Turn OFF the ignition.
2. Disconnect the fuel injector in-line
harness connector (H-125) from the
cylinder head cover case.
3. Remove the rubber fuel hose from the
fuel filter housing (fuel supply pump side).
Use a pan to catch the fuel leakage from
the removed fuel line.

Important:
The fuel vacuum pump/pressure gauge
connector and the adapter hose must be
cleaned before connecting to the fuel line.
Otherwise, foreign material internal to the
tools line may damage the fuel supply pump.

4. Connect the suction side fuel pressure

adapter 5-8840-2844-0 (EN-47667) with
fuel vacuum/pressure gauge assembly
5-8840-2844-0 (J-44638) in series with
the filter housing and the disconnected
5 fuel hose. Ensure the service tool and 8 inHg
fuel line connections are tight.
5. Bleed the fuel system by priming the
priming pump until it becomes firm, then
crank over the engine for a maximum of 5
seconds. Perform procedure three times.
6. Fully clamp off a fuel hose as close to the
fuel tank as possible (this will draw
vacuum on the fuel system). You can also
disconnect a fuel line and plug it.
7. Crank over the engine (for no longer than
15 seconds) while monitoring the fuel
pressure/vacuum gauge.

Notice:
Release the clamp or open the plug when the
gauge is likely to be more than 8 inHg during
the test.

Can a vacuum of at least the specified amount

be pulled on the fuel system? Go to Step 8 Go to Step 6
6C-12 Fuel System

Step Action Value(s) Yes No

1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper
clamps.
2. Draw fuel from the fuel tank at the fuel
line going to the fuel pickup tube to verify
6 a clean stream of fuel comes out (use the —
hand-held vacuum pump 5-8840-0279-0
(J-23738-A) with a clear hose or
equivalent) This will ensure the fuel
pickup tube is not cracked drawing air
into the fuel line.
3. Repair as necessary.

Did you find and correct the condition? Go to Step 18 Go to Step 7

1. Replace the fuel filter cartridge. Refer to
Fuel Filter Cartridge Replacement in this
section.
7 2. Retest the fuel system vacuum test 8 inHg
described in Step 5.

Can a vacuum of at least the specified amount

be pulled on the fuel system? Go to Step 18 Go to Step 17
1. Unclamp or unplug the fuel line from Step
5 and reconnect the fuel line.
2. Prime the priming pump until firmness is
felt.
3. Crank over the engine for 5 seconds.
4. Repeat steps 2 and 3 three times to bleed
8 the fuel system. 5 inHg

5. Crank over the engine (for no longer than

15 seconds at a time) while monitoring
the fuel pressure/vacuum gauge.

Does the vacuum/pressure gauge ever

indicate a larger than the specified value? Go to Step 9 Go to Step 10
1. Inspect the fuel lines between the fuel
supply pump and fuel tank for being
crushed or kinked.
2. Inspect the fuel tank vent hose for a
plugged or kinked condition.
3. Inspect the fuel cap for a plugged or
9 kinked condition. —
4. Inspect inside the fuel tank (if possible)
for any foreign material that may be
getting drawn into the fuel line pickup
causing a blocked condition.
5. Repair the condition as necessary.

Did you find and correct the condition? Go to Step 18 Go to Step 14

 Fuel System 6C-13

Step Action Value(s) Yes No

1. Turn OFF the ignition.
2. Make sure the fuel injector in-line harness
connector (H-125) is disconnected from
the cylinder head cover case.
3. Remove the eyebolt from the cylinder
head that connects to the leak-off pipe.
4. Connect the fuel adapter 5-8840-2845-0
(J-45873-103) with hose assembly to the
cylinder head. Install the hose into a
graduated cylinder from the 5-8840-2845-0
(J-45873-100) kit.
5. Remove the eyebolt from the pressure
limiter valve that connects to the leak-off
10 pipe. —
6. Connect the fuel adapter 5-8840-2845-0
(J-45873-105) with hose assembly to the
pressure limiter valve.
7. Crank over the engine for 10 seconds.
Make sure the batteries are fully charged
and the engine is cranking at normal
speed for each test.

Notice:
Perform this test three times and take the
average of the fuel return amount coming
from the cylinder head.

Is fuel leaking from the pressure limiter valve? Go to Step 15 Go to Step 11

Is the average fuel return coming from the
11 15ml
cylinder head less than the specified value? Go to Step 12 Go to Step 13
1. Remove each glow plug from the cylinder
head.
12 2. Inspect the tip of the plugs for wet fuel. —

Did you find wet fuel on any glow plug? Go to Step 16 Go to Step 17
1. Remove the cylinder head cover and
injector harness in order to connect the
fuel adapter 5-8840-2845-0 (J-45873-101)
with hose assembly to each injector leak-
off port. Refer to Fuel Injector
Replacement in this section.
2. Crank over the engine for 10 seconds.

Important:
13 Replacement injector must be programmed. 3ml
3. Replace the injector(s) that return fuel
more than the specified value. Refer to
Fuel Injector Replacement/Fuel Injector
ID Code Data Programming in this
section.
4. Retest after replacement of the fuel
injector(s).

Did you complete the replacement? Go to Step 18 —

6C-14 Fuel System

Step Action Value(s) Yes No

Replace the fuel filter cartridge. Refer to Fuel
14 Filter Cartridge Replacement in this section. —
Did you complete the replacement? Go to Step 18 —
Replace the pressure limiter valve. Refer to
15 Fuel Rail Replacement in this section. —
Did you complete the replacement? Go to Step 18 —
Important: Replacement injector must be
programmed.
Replace the appropriate injector(s) that was
16 leaking fuel found at Step. Refer to Fuel —
Injector Replacement/Fuel Injector ID Code
Data Programming in this section.

Did you complete the replacement? Go to Step 18 —

Important: The fuel supply pump must be
timed to the engine and adjustment value
must be learned to the ECM.
17 Replace the fuel supply pump. Refer to Fuel —
Supply Pump Replacement in this section.

Did you complete the replacement? Go to Step 18 —

1. Reconnect all previously disconnected
harness connector(s) or components.
2. Turn OFF the ignition for 30 seconds.
3. Bleed the air from the fuel system. Refer
to Fuel System Air Bleeding in this
section. ±5 MPa
18
4. Start the engine and let idle. (±725 psi)

5. Observe the Differential Fuel Rail

Pressure parameter with the Tech 2.

Is the Differential Fuel Rail Pressure

parameter within the specified value? System OK Go to Step 1

Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description Description
5-8840-2844-0
Fuel Pressure / Vacuum
Gauge Set
(J-44638 [Fuel Pressure / 5-8840-0279-0
Vacuum Gauge (J-23738-A)
Assembly] Vacuum Pump
EN-47667 [Suction Side
5884028440 Fuel Pressure / Vacuum
5884002790
Gauge Adapter])
 Fuel System 6C-15

Tool Number /
Illustration
Description

5-8840-2845-0
Fuel Test Adapter Set
(J-45873 / Fuel Test
Adapter Kit,
J-45873-100 / Fuel Test
Adapters)
5884028450
6C-16 Fuel System

Fuel Filter Assembly

Components

N6A6364E

Legend
1. Filler Cap 4. Bolt
2. Fuel Hose 5. Fuel Filter Assembly
3. Fuel Sedimenter Connector

Removal
1. Remove the filler cap.
2. Remove the fuel sedimenter connector and the clip
on the bracket.
3. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
4. Remove the bolts for mounting the fuel filter.
5. Remove the fuel filter assembly.

Installation
1. Install the fuel filter assembly.
2. Install the bolts for mounting the fuel filter.
3. Install the inlet hose and the outlet hose.
4. Install the fuel sedimenter and clip the cable to the
bracket.
5. Install the filler cap.
6. Bleed out the air.
• Refer to “Fuel System/Air bleeding”.
 Fuel System 6C-17

Fuel Filter Cartridge

Removal 2. Clean the cartridge mounting surface in the filter
body so that the cartridge can be seated securely.
1. Remove the cartridge using the filter wrench.
3. Coat a thin layer of fuel on the O-ring in the new
Special tool cartridge.
Filter wrench: 5-8840-0253-0 (J-22700) 4. To simplify air bleed, fill light oil on the new
2. Remove the sedimenter sensor. cartridge.
5. Tighten the cartridge until the O-ring touches the
sealing surface. During this process take adequate
care that the fuel inside does not flow out.
6. Use the filter wrench and tighten rotating by 1/3 to
2/3.

Special tool
Filter wrench: 5-8840-0253-0 (J-22700)

N6A6365E

Legend
1. O-Ring
2. Cartridge
3. Sedimenter Sensor
4. Fuel Heater Connector

N6A6366E
Installation
1. Assemble the sedimenter sensor in the new
cartridge.

Special Tool
Tool Number /
Illustration
Description / Remarks

5-8840-0253-0 (J-22700)
Filter Wrench

5884002530
6C-18 Fuel System

Fuel Injector
Components

13

12

N6A6367E

Legend
1. Fuel Injection Pipe Clip 8. EGR Valve Gasket
2. Fuel Injection Pipe 9. EGR Valve
3. Fuel Injector Leak-off Pipe 10. EGR Valve Gasket
4. Fuel Injector 11. Cylinder Head Cover
5. Fuel Injector Clamp 12. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 13. Fuel Injector Terminal
7. EGR Adapter

The fuel system consists of many tiny holes and removal and installation procedure.
spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to Caution:
extremely high precision. This is especially true of the To avoid electric shock;
fuel injectors. Set the switch to the ‘OFF’ position and disconnect
The fuel injector is very sensitive to foreign material. battery negative cable before checking or repairing the
Foreign material will result in fuel system breakdown. fuel injector, wiring or/and connectors.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
 Fuel System 6C-19
Important: 5. Remove the head cover.
The Fuel Injector ID Code Data Programming MUST be
done when the fuel injector is being replaced. The Fuel
Injector ID Code information MUST be recorded before 1
assembling the cylinder head cover.

Removal
1. Remove the engine harness, the throttle position
sensor, the EGR valve, the pressure sensor, and
all of the fuel injector connectors.
2. Remove the EGR valve and the EGR adapter.
3. Tape the EGR case holes shut to prevent the entry
of foreign material.

N6A6027E

Legend
1. Sound Insulation Cover (For Europe)
2. Head Cover

6. Loosen the fuel injector terminal nuts.

7. Loosen the fuel injector harness bracket bolts.
Remove the inside connector and the harness
bracket.
8. Remove the fuel injector leak-off pipe.
9. Remove the lower cover.

N6A6368E

Legend
1. EGR Adapter
2. EGR Valve

4. Remove the sound insulation cover.

N6A6124E

Legend
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak-off Pipe
6C-20 Fuel System
10. Remove the fuel injection pipe clips and the Special tools
injection pipes. Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)

N6A6128E
N6A6129E
Legend
1. Fuel Injection Pipe Legend
2. Pipe Clip 1. Sliding Hammer
2. Remover
11. Loosen the fuel injector clamp fixing bolts and 3. Fuel Injector Assembly
remove the fuel injectors.
If the fuel injectors are difficult to remove, use the fuel 12. Mark each fuel injector with the number of the
injector remover. Install the fuel injector remover to the cylinder from which it was removed. Store the fuel
leak-off pipe attachment part on the fuel injector. Use a injectors in a safe place. Position the fuel injector
sliding hammer to force the fuel injector clamp off the so that the nozzle is protected.
fuel injector.
Caution:
Caution: • Do not tamper with the electromagnetic portion of
Do not remove the fuel injector sleeve. the fuel injector. Reduced electromagnetic function
will result in injector failure.
 Fuel System 6C-21
Recording from the each fuel injector ID plate
Record 24 figures of each fuel injector ID plate. The
correct order for the fuel injector ID code for the
following illustration is as follows:
56 00 D1 CA 00 00 EC 00 23 14 21 B7

2 1

5600 D1CA
0000 EC00
2314 2100
0000 B7

3
N6A6370E

Legend
1. Gasket
2. Fuel Injector
3. Bolt
N6A6524E
4. Fuel Injector Clamp
Legend 2. Apply molybdenum to the threads and seating
1. Fuel Injector ID Plate surfaces of the clamp bolts.
2. Fuel Injector ID Code
3. Fuel Injector 3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface
Installation of the fuel injector side sleeve nuts.
6. Install the fuel injection pipes to the position shown
Important:
in the illustration.
Install each of the fuel injectors on its original position.
(the cylinder from which it was removed) 7. Use a spanner to carefully the sleeve nuts until the
fuel injection pipes contact the fuel injector and
1. Install a new gasket and O-ring to each of the fuel common rail.
injector clamps. Refer to the illustration. 8. Tighten the fuel injection pipe clips to the specified
torque.

Tighten:
Clips to 6 N⋅m (0.6 kg⋅m/52 lb⋅in)
6C-22 Fuel System

N6A6179E

Legend
1. Clamp Bolt
2. Sleeve Nut

11. Install the nozzle leak-off pipes together with the

new gaskets. Tighten the pipes to the specified
torque.

Tighten:
N6A6128E Pipes to 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
Legend
1. Fuel Injection Pipe
1. Pipe Clip

9. Final tighten the injection clamp bolts to the

specified torque.

Tighten:
Bolts to 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
10. Tighten the injection pipes to the specified torque.

Tighten:
Injection pipes to 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)

N6A6181E

12. Install the fuel injector harness connectors. Work

from the inside out.
13. Install the harness bracket and tighten the bolts to
the specified torque.

Tighten:
Bolts to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
 Fuel System 6C-23

N6A6182E N6A6029E

14. Install the fuel injector terminal nuts to the injector. 17. Install the sound insulation cover (For Europe).

Tighten: Tighten:
Nut to 2 N⋅m (0.2 kg⋅m/17 lb⋅in) Bolts to 8 N⋅m (0.8 kg⋅m/6 lb⋅ft)

Caution:
• Do not overtighten the nuts. Damage to the
1
terminal studs will result.
• The terminal nut with two wires is engine front
side.

2
1

N6A6027E

Legend
1. Sound Insulation Cover (For Europe)
2 2. Head Cover

18. Install the gasket to the EGR valve and tighten the
N6A6627E
bolts to the specified torque.
Legend
1. Fuel Injector Tighten:
2. Harness Bolts to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
3. Terminal Nut 19. Install the gasket to the EGR adapter and tighten
the bolts to the specified torque.
15. Install the gasket to the cylinder head cover.
Tighten:
16. Install the cylinder head cover and tighten up Bolts to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
according to the order.

Tighten:
Bolts to 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
6C-24 Fuel System

2 1

5600 D1CA
0000 EC00
2314 2100
0000 B7

N6A6371E N6A6525E

Legend Legend
1. EGR Adapter 1. Fuel Injector ID Plate
2. EGR Valve Gasket 2. Fuel Injector ID Code
3. EGR Valve 3. Fuel Injector
4. EGR Valve Gasket
5. After complete the registration, turn OFF the
20. Attach the engine harness connectors. Each ignition for 30 second.
composite connector should make a loud click 6. Turn ON the ignition.
when it is securely attached.
7. Select Diagnostics > appropriate vehicle
identification > 4HK1 (Common Rail) >
Fuel Injector ID Code Data Programming Procedure
Programming > Injector ID Code > Injector ID
1. Install the Tech 2. Code. At this point, all registered fuel injector ID
2. Turn ON the ignition, with the engine OFF. code data can be verified. Compare the ID code
3. Select Diagnostics > appropriate vehicle values registered into the ECM and each fuel
identification > 4HK1 (Common Rail) > injector including the last 2 figures. If the registered
Programming > Injector ID Code > ID Code ID code is incorrect, go back to Step 4 ID Code
Registration. Registration.
4. Select replaced cylinder and press Change. Input 8. Start the engine and let idle.
22 figures. Then, input in order from the left edge 9. Inspect for a proper engine running condition and
of upper sequence to the right sequence. The for no DTC’s. Refer to the Diagnostic System
correct order for the fuel injector ID code for the Check-Engine Controls if needed.
following illustration is as follows:
56 00 D1 CA 00 00 EC 00 23 14 21 Notice:
After replacement of the fuel injector, perform the
Important: following procedure.
The number of places required for input is 22 figures All fuel injectors are replaced:
except last 2 figures. Remove the fuel injector ID code label on the cylinder
head cover.
Any fuel injector(s) is replaced:
Blackout the replaced cylinder fuel injector ID code on
the cylinder head cover with a marking pen or
equivalent.
 Fuel System 6C-25
Torque Specifications

N6A6656E

Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description / Remarks Description / Remarks

5-8840-2826-0
5-8840-0019-0 (J-23907)
(EN-46720)
Sliding Hammer
Fuel Injector Remover

5884000190 EN46720
6C-26 Fuel System

Fuel Supply Pump

Components

N6A6373E

Legend
1. Fuel Leak-off Pipe 5. Bracket
2. Fuel Pipe 6. Bracket O-ring
3. Fuel Supply Pump 7. Drive Gear
4. O-ring 8. Oil Drain Adapter

The fuel system consists of many tiny holes and

spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
removal and installation procedure.

Important:
The Fuel supply pump must be timed to the engine.

Removal
1. Remove the intake pipe and the intake throttle
valve. N6A6374E
2. Remove the fuel pipe and fuel leak-off pipe.
3. Remove the fuel feed hose.
 Fuel System 6C-27
4. Disconnect the fuel temperature sensor and the
fuel rail pressure regulator harness connector from
the fuel supply pump.
5. Remove the fuel supply pump attachment bolts
and nuts, then remove the fuel supply pump.

Notice:
One of the attachment bolt (1) secures the fuel supply
pump to the flywheel housing as denoted in the picture
below.

N6A6377E

Legend
1. Fuel Supply Pump
2. O-ring
3. Fuel Supply Pump Bracket

Installation
1. Install the O-ring to the fuel supply pump.
2. Install the pump to the bracket and tighten the 3
N6A6375E
bolts to the specified torque.
6. Use a gear puller to remove the fuel supply pump
gear and the O-ring. Tighten:
Bolts to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

Caution:
Take care not to twist the O-ring.

N6A6376E

7. Loosen the 3 bolts holding the fuel supply pump

bracket. Remove the bracket and the O-ring.

N6A6377E

Legend
1. Fuel Supply Pump
2. O-ring
3. Fuel Supply Pump Bracket
6C-28 Fuel System
3. Align the fuel supply pump shaft key and gear. 5. Turn the crankshaft in the normal direction of
Install the gear and tighten the nut to the specified engine rotation until the No. 1 or No. 4 cylinder is
torque. at TDC on the compression stroke.
There is a round alignment mark on the gear Refer to the illustration.
(white paint).

Tighten:
Nut to 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)

N6A6003E

Notice:
There are 2 timing marks on the crankshaft pulley.
N6A6378E Mark (1) is near the front cover and is used to bring the
Legend 4HK1-TC engine to TDC.
1. Fuel Supply Pump Mark (2) is not applicable to this engine.
2. Fuel Supply Gear Be sure to use mark (1) when bringing the engine to
3. Nut TDC.

4. Apply white paint to the top of the fuel supply pump

gear tooth directly above the stamped ‘O’ mark.
Refer to the illustration.

N6A6002E

6. Remove the oil drain adapter.

7. Install the O-ring to the fuel supply pump.
8. Align the slits as shown in the illustration.
N6A6379E
9. Insert the stud bolts into the guides and
temporarily tighten them.
 Fuel System 6C-29
Caution:
Tighten:
• If the stud bolts (cylinder block side) have been Bolt to 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
loosened or replaced, apply Loctite 262 to the
recessed portion of the bolts.

N6A6081E

N6A6079E Legend
• Check that the round alignment mark (white paint) 1. Oil Drain Adapter
is positioned as shown in the illustration when 2. O-ring
viewed from the plug hole. If necessary, reposition
the gear. 12. Connect the fuel temperature sensor and the
suction control valve connectors to the fuel supply
• Tighten the stud bolts and the nuts to the specified pump.
torque.
13. Install the fuel feed hose.
Tighten: 14. Install the throttle assembly.
Nut to 50 N⋅m (5.1 kg⋅m/37 lb⋅ft)
• Coat the fluid gasket and mount within 7
Bolt to 76 N⋅m (7.7 kg⋅m/56 lb⋅ft) minutes.

Tighten:
Throttle assembly to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
• Install the intake throttle valve chamber hose.

N6A6080E

Legend
1. Plug Hole
2. Alignment Mark
N6A6380E
10. Apply a light coat of engine oil to the O-ring. Legend
11. Install the oil drain adapter to the plug hole. 1. Intake Throttle Valve Chamber
Tighten the bolt to the specified torque.
15. Install the fuel pipe and fuel leak-off pipe.
6C-30 Fuel System
Important: 16. Inspect for a proper engine running condition and
In order to make the fuel supply pump characteristic for no DTC’s. Refer to the Diagnostic System
learn into the ECM, let the engine idle until warm-up. If Check-Engine Controls if needed.
the fuel system DTC’s stored in the meantime, once
clear DTC and warm-up the engine again.

Torque Specifications

N6A6381E
 Fuel System 6C-31

Fuel Rail
Components

N6A6382E

Legend
1. Fuel Leak-off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Fuel Rail
4. EGR Valve Gasket 9. Fuel Rail Bracket
5. EGR Adapter

Parts of the fuel system such as the internal part of the Removal
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy. WARNING:
They are therefore highly sensitive to foreign matter TO PREVENT LEAKED FUEL FROM CATCHING
and the entry of foreign matter could cause damage to FIRE, DO NOT WORK WHILE THE ENGINE IS HOT.
the fuel passage. Therefore, effective measures should
be taken to prevent the entry of foreign matter. Preparation:
• Pour detergent into a steam cleaner, and throughly
wash around the sensor and the fuel rail.
• Remove water completely using air blow.
6C-32 Fuel System
Notice: 6. Remove the injection pipe clip and remove the
Make sure that foreign matter will be prevented from injection pipes.
getting in.
Important:
1. Remove the air intake pipe. Loosen the injection pipes gradually not to scatter high
• Disconnect the connector for the intake air pressure fuel.
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
connectors.
4. Remove the EGR valve and the EGR adapter.
5. Tape the EGR case holes shut to prevent the entry
of foreign material.

N6A6128E
N6A6368E
Legend
Legend 1. Fuel Injection Pipe
1. EGR Adapter 2. Fuel Injection Pipe Clip
2. EGR Valve
7. Remove the fuel pipe.

Important:
Loosen the fuel pipe gradually not to scatter high
pressure fuel.
 Fuel System 6C-33
8. Remove the clips and the fuel leak-off pipe. Disassembly
1. Remove the fuel pressure limiter.
2. Remove the fuel rail pressure sensor.

3 2
N6A6383E

Legend
1. Fuel Pipe
N6A6385E
2. Fuel Leak-off Pipe
Legend
9. Remove the fuel rail and the fuel rail bracket. 1. Fuel Rail
2. Fuel Rail Pressure Sensor
• Do not remove the flow damper.
3. Fuel Pressure Limiter
The dampers should always remain in the fuel
4. Flow Damper
rail.
• Take care not to damage the connector unit of
the pressure sensor.
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)

N6A6384E

Legend
1. Fuel Rail Bracket
2. Fuel Rail
6C-34 Fuel System
3. Tighten the fuel leak-off pipe (1) using the
mounting eyebolt and the clips using the specified
torque.
4
Tighten:
(2) to 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
1
(3) to 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
(4) to 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) to 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
(7) to 6 N⋅m (0.6 kg⋅m/52 lb⋅in)
3 2
(8) to 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)

N6A6385E

Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter
4. Flow Damper

Installation
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 N6A6386E
torque. 5. Install the fuel leak-off hose to the fuel leak-off
Tighten: pipe.
Bolts to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft) 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)

Tighten:
Injection pipe clip to 6 N⋅m (0.6 kg⋅m/52 lb⋅in)

N6A6384E

Legend
1. Fuel Rail Bracket
2. Fuel Rail
 Fuel System 6C-35
• Apply a thin coat of engine oil on the periphery
of the sleeve nut on the fuel injector side and
assemble.

N6A6371E

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.

N6A6128E

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:
Bolt 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: N6A6121E
Bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
6C-36 Fuel System
Torque Specifications

N6A6387E
 Fuel System 6C-37

Fuel Sedimenter Switch

Inspection
1. Check that there is continuity between the switch
connector terminals when the float in the fuel
sedimenter is above the water drain line.
2. Turn on the ignition switch, disconnect the fuel
sedimenter connector, and connect the terminals
of the connectors on the vehicle side. Confirm that
the sedimenter warning lamp lights up.
If abnormalities are detected during the check, replace
the switch parts and carry out repairs in case of
defective connection between circuits or short circuits.

Sedimenter Sedimenter
Switch Switch

Heater Heater
N6A6388E

Legend
1. Sensor
2. Connector on The Vehicle Side
3. Harness
4. Drain Cock
6C-38 Fuel System

Fuel Tank
Components

3
1
2 4

N6A6389E

Legend
1. Fuel Gauge Unit Connector 4. Fuel Return Hose
2. Evaporated Fuel Hose 5. Band
3. Fuel Feed Hose 6. Fuel Tank

Removal 6. Remove the fuel feed hose.

1. Loosen the fuel filler cap. 7. Remove the fuel return hose.
2. Drain the fuel from the drain plug. • Plug the hose so that fuel does not flow out,
and tie it to the frame-side with the opening
3. After draining, tighten the drain plug with the
faced up.
specified torque.
8. Remove the nut of band which installs fuel tank,
Tighten: and remove the band tip in the frame-side.
20 N⋅m (2.0 kg⋅m/15 lb⋅ft)
9. Pull out the fuel tank to the outside.
4. Remove the fuel gauge unit connector.
5. Remove the evaporated fuel hose.
 Fuel System 6C-39
Caution: 6. Connect the fuel gauge unit connector.
If the fuel tank cannot be pulled out, remove the bracket
and pull out the fuel tank downward.

2
3

N6A6390E

Legend
1. Fuel Gauge Unit Connector
2. Fuel Gauge Unit
3. Cross-member
4. Fuel Tank

Installation
1. Install the fuel tank.

Caution:
When the bracket has been removed while taking out
the fuel tank, attach the bracket to the frame and
tighten it to the specified torque.

Tighten:
55 N⋅m (5.6 kg⋅m/41 lb⋅ft)
Also, when placing the fuel tank on the bracket, make
sure that the rubber part attached on the fuel tank is put
onto the bracket.
2. Install the band to the fuel tank and tighten up the
nuts with the specified torque.

Tighten:
12 N⋅m (1.2 kg⋅m/9 lb⋅ft)
3. Install the fuel return hose.
4. Install the fuel feed hose.
• Insert the hose into the pipe for more than 25
mm (1.0 in).
5. Install the evaporated fuel hose.
• Fill the fuel tank with fuel, and tighten the fuel
filler cap.
• Connect the battery earth cable.
• Make sure there is no fuel leakage from the
connector parts of hoses after starting the
engine.
6C-40 Fuel System

Fuel Gauge Unit

Components

N6A6391E

Legend
1. Fuel Gauge Unit Connector 2. Fuel Gauge Unit

Removal Inspection
1. Remove the wiring connector from the fuel gauge The fuel tank unit changes the internal resistance
unit. according to the float position (fluid level) to operate the
2. Remove the installed screw and remove the fuel indicator of the fuel meter.
gauge unit.

Caution:
When removing/installing the fuel gauge unit, take care
not to interfere with adjacent parts and not to let the F
arm etc. deformed. Also, after removing the fuel gauge
unit, cover the tank with a cloth to prevent the entry of
dust.

E
N6A6392E
 Fuel System 6C-41
1. While moving the float from “E” to “F”, measure the Installation
resistance between the connector terminals 1J-28
Assemble in the reverse order of disassembly.
and 2J-28.
1. Install the fuel gauge unit.
2. Check that the fuel level warning lamp comes on
when the float is at “E” position. If the result of the 2. Connect the wiring connector to the fuel gauge
inspection is unsatisfactory, replace with a new unit.
part.

Tightening Torque Specifications

N m (kg m / lb ft)
55 (5.6 / 41)

12 (1.2 / 9)

20 (2.0 / 15)

N6A6394E