Isuzu Trooper (1998-2002 year). Manual - part 578

6C – 8 ENGINE FUEL

REASSEMBLY

1. Clean the cartridge mounting surface of the filter

body so that the cartridge can be secured.
Apply engine oil thinly to new cartridge O-ring.

2. To facilitate bleeding, fill the new cartridge with light

oil.

3. Tighten the cartridge until O-ring comes in contact

with the seal, taking care not to spill the light oil.

4. Retighten 1/3 – 2/3 using a filter wrench.

Filter wrench: 5-8840-0203-0

Bleeding

1. Loosen air bleeding plug.
2. Operate priming pump to bleed the air in the fuel

line.

3. Operate the priming pump until the fuel is overflow

from air bleeding plug.

4. Tighten the air bleeding plug.
5. Start the engine, and if it is not started in 10

seconds or less, repeat the bleeding steps.

6. Make sure of no fuel leakage, and tighten the

priming pump.

Legend

(1) Priming Pump

NOTE: In comparison with the conventional engine,
the capacity of fuel passage in the 4JX1 engine is
larger. It takes the priming pump more time to fill the
engine with fuel.

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1

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ENGINE FUEL 6C – 9

INJECTOR

2

1

6

With
spacer type

Without
spacer type

8

9

3

4

7

5

Legend

(1)

Nut and Washer

(2)

Injector Clamp

(3)

Nut

(4)

Bolt

(5)

Oil Rail Assembly

(6)

Spacer (If equipped) and Bolt

(7)

Injector Assembly

(8)

Gasket

(9)

O-Ring

012R200006

6C – 10 ENGINE FUEL

REMOVAL

Prior to removal, be sure to confirm and record the
group code of the injector installed using Tech2.

1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler.

Refer to “Intercooler” in this manual.

4. Remove PCV hose and pipe.
5. Remove cylinder head noise insulator cover.
6. Remove high pressure oil pipe.

CAUTION:

1) Sleeve nut should be loosened with cloth tied

around to prevent oil from spurting due to the
remaining pressure.

2) High oil pressure pipe should be disconnected

with cloth tied around the intake manifold glow
plug to prevent oil from flowing out of the oil
rail.

7. Loosen eye bolt of fuel pipe at fuel pump side.

NOTE: Cloth should be put around the loosened eye
bolt to prevent fuel from flowing out.

8. Remove fuel return hose at chassis side.
9. Remove PCV hose to cylinder head cover.

10. Remove cylinder head cover.
11. Drain the oil from oil rail assembly.

NOTE: Do not drop O-ring 

12. Record the grade code of injector for each cylinder

that is indicated on the upper portion of injector.
There are nine kinds of grade code available, one
alphabet letter and one numeral letter.

Grade code

Legend

(1) Part Number
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code

13. Remove harness connector from each injector.
14. Loosen nuts and bolts for oil rail.
15. Remove injector fixing bolts.
16. Remove injector clamp.
17. Remove injector assembly.

INSTALLATION

1. Install oil rail, tighten temporarily
2. Install injector assembly.

NOTE:

1) Do not forget to install O-ring between injector and

oil rail.

2) Use new O-ring
3) Clean O-ring groove and fitting surface of parts.
4) Apply engine oil to O-ring.

3. Install injector fixing bolts, tighten temporarily.
4. Install injector clamp, tighten nut temporarily.

· Apply engine oil to washer both side.

5. Tighten injector fixing bolts to the specified torque.

Torque: 7 N·m (0.7 kg·m / 61 lb in)

6. Tighten injector clamp nut to the specified torque

with special method.

Torque: 30 N·m (3.1 kg·m / 22 lb ft) then loosen a
time again tighten as following torque.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)

7. Tighten oil rail to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

1

4

3

2

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Category number

A –  1
A –  2
A –  3

B – 1
B – 2
B – 3

C – 1
C – 2
C – 3

ENGINE FUEL 6C – 11

8. Install injector harness assembly, reconnect

harness connecter to injector.

9. Record the identification marking of injector for

each cylinder that is indicated on the upper portion
of injector.

Legend

(1) Part Number
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code

10. Install cylinder head assembly.

Refer to “Cylinder Head” in this manual.

11. Fill with about 300cc of engine oil from the high

pressure oil pipe installation port of the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.

12. Immediately install high pressure oil pipe and

tighten to specified torque.

Torque: 78 N·m (8.0 kg·m / 58 lb ft)
13. Install cylinder head noise insulator cover.

Refer to “Cylinder Head” in this manual.

14. Install intercooler assembly.

Refer to “Intercooler” in this manual.

15. Install air cleaner cover and air duct.
16. Use TECH2 to rewrite injector data to ECM.

For rewriting method refer to section “Data
Programming in Case of ECM Change” of section
6E 4JX1 engine driveability and emissions in this
manual.

NOTE:

1) On completion of servicing, bleed air from the

engine inside fuel passage by means of the priming
pump. (The priming pump should be operated more
times than in the case of conventional engines.)

2) As air is in the oil rail, it takes more time to start the

engine. Rough idling may occur while the air is
being bled completely after engine start, but it does
not indicate trouble.
The air will be bled and normal engine status will be
reached while the vehicle is driven for about 5 km
or engine is operated for about 5 minutes at 1500 to
2000 rpm.

3) The injector spare part will be provided for group

number B1, B2 and B3 only.

Injector Grade code Programming
(Injector Change)

In case of an injector change, the injector grade code
(category number) must be programmed by Tech-2.

Programming Procedure

1. Connect the Tech-2 to the vehicle DLC.
2. Turn the starter switch to the “ON” position.
3. Select the “Diagnosis” from the Main menu.
4. Select the “Programming” from the Application

menu.

1

4

3

2

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F0 : 

Diagnostic Code

F1 : 

Data Display

F2 : 

Snapshot

F3 : 

Miscellaneous Test

F4 : 

Programming

Application Menu

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