Isuzu N-Series. Service manual - part 526

 

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Isuzu N-Series. Service manual - part 526

 

 

6C-12   Fuel System

6

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
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

7

1.

Replace the fuel filter cartridge. Refer to
Fuel Filter Cartridge Replacement in this
section.

2.

Retest the fuel system vacuum test
described in Step 5.

Can a vacuum of at least the specified amount
be pulled on the fuel system?

8 inHg

Go to Step 18

Go to Step 17

8

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
the fuel system.

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?

5 inHg

Go to Step 9

Go to Step 10

9

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
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

Step

Action

Value(s)

Yes

No

Fuel System   6C-13

10

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
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

11

Is the average fuel return coming from the
cylinder head less than the specified value?

15ml

Go to Step 12

Go to Step 13

12

1.

Remove each glow plug from the cylinder
head.

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

13

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:
Replacement injector must be programmed.

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?

3ml

Go to Step 18

Step

Action

Value(s)

Yes

No

6C-14   Fuel System

Special Tool

14

Replace the fuel filter cartridge. Refer to Fuel
Filter Cartridge Replacement in this section.

Did you complete the replacement?

Go to Step 18

15

Replace the pressure limiter valve. Refer to
Fuel Rail Replacement in this section.

Did you complete the replacement?

Go to Step 18

16

Important: Replacement injector must be
programmed.
Replace the appropriate injector(s) that was
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

17

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

Did you complete the replacement?

Go to Step 18

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.

4.

Start the engine and let idle.

5.

Observe the Differential Fuel Rail
Pressure parameter with the Tech 2.

Is the Differential Fuel Rail Pressure
parameter within the specified value?

±5 MPa

(

±725 psi)

System OK

Go to Step 1

Step

Action

Value(s)

Yes

No

Illustration

Tool Number / 

Description

5-8840-2844-0

Fuel Pressure / Vacuum 

Gauge Set

(J-44638 [Fuel Pressure / 

Vacuum Gauge 

Assembly]

EN-47667 [Suction Side 
Fuel Pressure / Vacuum 

Gauge Adapter])

 5884028440

5-8840-0279-0

(J-23738-A)

Vacuum Pump

Illustration

Tool Number / 

Description

5884002790

Fuel System   6C-15

5-8840-2845-0

Fuel Test Adapter Set

(J-45873 / Fuel Test 

Adapter Kit, 

J-45873-100 / Fuel Test 

Adapters)

Illustration

Tool Number / 

Description

5884028450

 

 

 

 

 

 

 

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