6C – 62 FUEL SYSTEM

INJECTION VOLUME ADJUSTMENT

TEST CONDITIONS
4HG1-T

Item Condition
Injection nozzle and holder assembly Bosch AS Part No.: 105118-7541
Injection nozzle Bosch AS Part No.: 105017-2650
Nozzle holder Bosch AS Part No.: 105048-4280
Injection nozzle opening
2 184 (2,616/18,044)
pressure kg/cm (psi/kPa)
Injection line dimensions
Inside diameter mm (in) 2.2 (0.086)
Outside diameter mm (in) 6.0 (0.236)
Length mm (in) 600 (23.6)
2
Fuel delivery pressure kg/cm (psi/kPa) 2.6 (36.97/254.9)
Test fuel SAE Standard Test Diesel Fuel (SAE J967d)
ISO Standard Test Diesel Fuel (ISO 4113)
Test fuel temperature °C (°F) 40 - 45 (104 - 113)
Identification numbers 101401-7452

IDENTIFICATION PLATE AND NUMBER

Use the data following the injection pump identification
number to adjust the injection volume.

6C-59-1.tif
 FUEL SYSTEM 6C – 63

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Identification Numbers : 101401-7452
[4HG1-T Engine]
Pre-stroke : No. 1 plunger 3.8 ± 0.05 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 30') Plungers are numbered from the Governor side
Tappet clearance : Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.
: Bolt adjustment type : More than 0.3 mm for all cylinders.

Injection Volume

Rack Pump Injection q’ty Max var

Adjusting 3
Position Speed (cm /1000 bet. cyl. Fixed Remarks
point
(mm) (rpm) strokes) (%)
11.5 1000 73.5 ± 1.6 ±4 Rack Basic
(Measure)
H Approx. 8.9 315 ±10 Rack
± 1.3
Basic Boost press. kPa (mmHg)
A R1 (11.5) 1000 73.5 ± 1 - Lever
Above 62.0 (Above 465)
Boost press. kPa (mmHg)
B R1 +1.0 1500 (78.5) ± 2 - Lever
Above 62.0 (Above 465)
Boost press.
C R2 –0.8 500 (66.5) ± 2 - Lever
0
(Measure) Boost press.
I - 150 - Lever
± 16 0
Confirm that the timing of is
advanced 1°±30’ from A.

Timing Advance Specification

Pump speed Below

N1 N3
(rpm) (N1 + 50)
Advance Below Finish
Start
angle (°) 0.5 4.0 ± 0.5
6C – 64 FUEL SYSTEM

Governor Adjustment (4HG1-T)

040LX014.tif

040LX011.tif

040LX015.tif

040LX012.tif

040LX013.tif
040LX003.tif
 FUEL SYSTEM 6C – 65

INJECTION VOLUME ADJUSTMENT

TEST CONDITIONS
4HE1-T

Item Condition
Injection nozzle and holder assembly Bosch AS Part No.: 105048-3831
Injection nozzle Bosch AS Part No.: 105017-1840
Nozzle holder Bosch AS Part No.: 105048-3831
Injection nozzle opening
2 185 (2,631/18,142)
pressure kg/cm (psi/kPa)
Injection line dimensions
Inside diameter mm (in) 2.0 (0.079)
Outside diameter mm (in) 6.0 (0.236)
Length mm (in) 600 (23.6)
2
Fuel delivery pressure kg/cm (psi/kPa) 2.6 (36.97/254.9)
Test fuel SAE Standard Test Diesel Fuel (SAE J967d)
ISO Standard Test Diesel Fuel (ISO 4113)
Test fuel temperature °C (°F) 40 - 45 (104 - 113)
Identification numbers 101401-7410
101401-7420
101401-7273

IDENTIFICATION PLATE AND NUMBER

Use the data following the injection pump identification
number to adjust the injection volume.

6C-62-1.tif
6C – 66 FUEL SYSTEM

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Identification Numbers : 101401-7410/101401-7420/101401-7273
[4HE1-T Engine]
Pre-stroke : No. 1 plunger 3.8 ± 0.05 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 30') Plungers are numbered from the Governor side
Tappet clearance : Bolt adjustment type : More than 0.3 mm for all cylinders.
: Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.

Injection Volume

Adjusting Pump speed Injection volume Variance

Remarks
point (r.p.m.) (cc/1000 strokes) (%)
1,160 96.5 ± 1.6 ±4 Basic
H 375 14.5 ± 1.3 ±10.0
Z 375 - - Basic
A 1,160 96.5 ± 1 -
B 1,450 (97) ± 2 -
C 700 (81) ± 2 -
I 150 (100) + 18
− 0
-

Timing Advance Specification

1,185 1,450
Pump Speed (r.p.m.) 1,135
or less or more
0.5 Finish
Degree for Angle of Lead (deg.) Start
or less 4.8 ± 0.5
 FUEL SYSTEM 6C – 67

Governor Adjustment

040LW024.tif
040LW017.tif

040LW014.tif 040LW027.tif 040LW030.tif

040LW015.tif
6C – 68 FUEL SYSTEM

INJECTION VOLUME ADJUSTMENT

TEST CONDITIONS
4HE1-TC Engine

Item Condition
Injection nozzle and holder assembly Bosch AS Part No.: 105118-6460
Injection nozzle Bosch AS Part No.: 105017-2180
Nozzle holder Bosch AS Part No.: 105048-3673
Injection nozzle opening
2 185 (2,631/18,142)
pressure kg/cm (psi/kPa)
Injection line dimensions
Inside diameter mm (in) 3.0 (0.118)
Outside diameter mm (in) 8.0 (0.315)
Length mm (in) 600 (23.6)
2
Fuel delivery pressure kg/cm (psi/kPa) 2.6 (36.97/254.9)
Test fuel SAE Standard Test Diesel Fuel (SAE J967d)
ISO Standard Test Diesel Fuel (ISO 4113)
Test fuel temperature °C (°F) 40 - 45 (104 - 113)
Identification numbers 107492-1023
107492-1062
107492-1032
107492-1100
107492-1110
107492-1120
107492-1130
897212-9350 (ISUZU NO.)

IDENTIFICATION PLATE AND NUMBER

Use the data following the injection pump identification
number to adjust the injection volume.

6C-65-1.tif
 FUEL SYSTEM 6C – 69

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Identification Numbers : 107492-1110
[4HE1-TC Engine]
Pre-stroke : No. 1 plunger 4.0 ± 0.03 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 15') Plungers are numbered from the Governor side
Tappet clearance : Bolt adjustment type : More than 0.3 mm for all cylinders.
: Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.

Injection Volume

Adjusting Pump speed Injection volume Variance

Remarks
point (r.p.m.) (cc/1000 strokes) (%)
1000 82.5 ± 1.6 ± 4 Basic
H 400 19 ± 1.5 ± 14
Z 500 - -
A 1000 82.5 ± 1 - Basic
B 1,450 (92.5) ± 2 -
C 500 (67) -
D 1,450 (89.5) -
I 150 (220) -
6C – 70 FUEL SYSTEM

Governor Adjustment

040LX018.tif

040LX017.tif

040LX019.tif

040LW021.tif

040LW028.tif
 FUEL SYSTEM 6C – 71

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Identification Numbers : 107492-1023 / 107492-1100
[4HE1-TC Engine]
Pre-stroke : No. 1 plunger 4.0 ± 0.03 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 15') Plungers are numbered from the Governor side
Tappet clearance : Bolt adjustment type : More than 0.3 mm for all cylinders.
: Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.

Injection Volume

Adjusting Pump speed Injection volume Variance

Remarks
point (r.p.m.) (cc/1000 strokes) (%)
1,000 107.5 ± 1.6 ±4 Basic
H 400 22 ± 1.5 ±10.0
Z 510 - - Basic
A 1,000 107.5 ± 1 -
B 1,200 (112.5) ± 2 -
C 500 (78) -
D 1,200 (103) -
I 150 (235) -
6C – 72 FUEL SYSTEM

Governor Adjustment

ipf

040LW025.tif

040LW020.tif

040LW010.tif

040LW028.tif 040LW031.tif

040LW022.tif
 FUEL SYSTEM 6C – 73

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Identification Numbers : 107492-1062 / 107492-1120 / 897212-9350 (ISUZU NO.)
[4HE1-TC Engine]
Pre-stroke : No. 1 plunger 4.0 ± 0.03 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 15')-Plungers are numbered from the Governor side
Tappet clearance : Bolt adjustment type : More than 0.3 mm for all cylinders.
: Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.

Injection Volume

Adjusting Pump speed Injection volume Variance

Remarks
point (r.p.m.) (cc/1000 strokes) (%)
1,000 107.5 ± 1.6 ± 4 Basic
H 400 22 ± 1.5 ± 14
Z 510 - - Basic
A 1,000 107.5 ± 1 -
B 1,400 (121.5) ± 2 -
C 500 (78) ± 2 -
D 1,400 (113) -
I 150 (235) -
6C – 74 FUEL SYSTEM

Governor Adjustment

040LW019.tif 040LW025.tif

040LW010.tif
040LW023.tif

040LW028.tif
 FUEL SYSTEM 6C – 75

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Identification Numbers : 10749-1032 / 107492-1130
[4HE1-TC Engine]
Pre-stroke : No. 1 plunger 4.0 ± 0.03 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 15') Plungers are numbered from the Governor side
Tappet clearance : Bolt adjustment type : More than 0.3 mm for all cylinders.
: Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.

Injection Volume

Adjusting Pump speed Injection volume Variance

Remarks
point (r.p.m.) (cc/1000 strokes) (%)
900 78 ± 1.6 ± 4 Basic
H 400 19 ± 1.5 ± 14
Z 500 - - Basic
A 900 78 ± 1 -
B 1,450 (98.5) ± 2 -
C 500 (67.5) -
D 1,450 (91.5) -
E 700 (78) -
I 150 (220) -
6C – 76 FUEL SYSTEM

Governor Adjustment

040LW025.tif
040LW018.tif

040LW011.tif 040LW028.tif 040LW031.tif

040LW021.tif
 FUEL SYSTEM 6C – 77

ANEROID COMPENSATOR ADJUSTMENT

6C-74-1.tif
6C – 78 FUEL SYSTEM

INJECTION VOLUME ADJUSTMENT

4HE1-TC (4HE1-XS) Engine for EURO3
1. TEST CONDITION
Item Condition
Injection nozzle and holder assembly Bosch AS Part No.: 105780-8250
Injection nozzle Bosch AS Part No.: 105780-0120
Nozzle holder Bosch AS Part No.: 105780-2190
Injection nozzle opening
2 211 (3,000/20.7)
pressure kg/cm (psi/MPa)
Injection line dimensions
Inside diameter mm (in) 3.0 (0.118)
Outside diameter mm (in) 8.0 (0.315)
Length mm (in) 600 (23.6)
2
Fuel delivery pressure kg/cm (psi/kPa) 2.6 (36.97/254.9)
Test fuel SAE Standard Test Diesel Fuel (SAE J967d)
ISO Standard Test Diesel Fuel (ISO 4113)
Test fuel temperature °C (°F) 40 - 45 (104 - 113)
Identification numbers 107492-1162
897225-4321 (ISUZU No.)

2. INJECTION TIMING
Pre-stroke : No. 1 plunger 4.0 ± 0.03 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 15') Plungers are numbered from the Governor side
Tappet clearance : Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.
 FUEL SYSTEM 6C – 79

3. INJECTION TIMING ADJUSTMENT

(Refer to the MITICS Repair and Maintenance Service Manual
for adjustment details.)
3 6 5
3.1 Adjustment Preparation
1) install setscrew ! (P/N 157927-2820), screw "
(P/N 157927-3321) and solenoid switch # into
4 housing $.
2) -1. Screw in setscrew ! until the counterweight
contacts the housing’s pressfitted stopper pin.
-2. Tighten screw " until clearance between screw
" and counterweight % is 1～2 mm.
1 -3. Tighten solenoid switch # until clearance
between solenoid switch and counterweight %’s
2
pin is 1～2 mm, then tighten locknut&.
3) Install starting advance mechanism’s cover.
• Setscrew installation 4) Position control rack in full position.
5) Set power supply voltage to manual controller at 12V.

3.2 Pre-stroke adjustment

Adjust No.1 cylinder’s start of static injection using the
shim $.
3.3 Individual cylinder’s injection order adjustment
Adjust difference between each cylinder’s injection angle
based on that of the No.1 cylinder using the shim $.

040L200014

• Pre-stroke adjustment
• Individual cylinder’s injection order
adjustment
6C – 80 FUEL SYSTEM

3.4 Measuring pre-stroke output voltage

1) Install the measuring device (P/N 105782-6420).
2) Remove the setscrew ! (P/N 157927-2820) and
install the air bleeder bolt.
3) Screw in screw " (P/N 157927-3321) and measure
the No 1 cylinder’s output voltage for pre-stroke lift
values in the table below.

Output
Adjusting point Pre-stroke
voltage Remarks
confirmation point (mm)
(actual)
3.70 a1 + tolerance
a
3.44 a2 - tolerance
3.24 b1 + tolerance
b
3.04 b2 - tolerance
(calculate form each specification)

Advice
If measuring device (P/N 105782-6420) is removed, the
output voltage (a1, a2) should be remeasured.

3.5 Minimum advance angle adjustment stopper

adjustment
1) Remove the screw " (P/N 157927-3321) and install
minimum advance angle adjustment stopper.
2) Screw in minimum advance angle adjustment
stopper until No 1 cylinder’s pre-stroke is 3.84～3.90.
Then, tighten locknut to specified torque.
3) Measure the output voltage (c) at this time.

3.6 Solenoid switch adjustment

1) Apply 24 V voltage to solenoid switch #.
2) Loosen solenoid switch # until No 1 cylinder’s pre-
stroke is 1.90～2.03 mm, then tighten the locknut to
the specified torque.
3) Confirm solenoid switch operates at 14.5 – 0.1 V.
 FUEL SYSTEM 6C – 81

4. GOVERNOR AJUSTMENT
4.1 Governor adjustment

FULL ROAD ADJUSTMENT IDLING ADJUSTMENT

CONTROL RACK POSITION(mm)

BOOST COMPENSATOR Confirm rack sensor
STROKE:1.65±0.1
CONTROL RACK POSITION(mm)

Vist=2.77±0.28
10.5 at supply voltage 5±0.01V,
TORQUE CAM 10.0±0.1
B H J N=1000r/min, R=R1(16.1)
R1+0.45 No. "AG80" Approx. 8.7
A D 7.8
Approx. R1+0.05
6.6±0.1
R1(16.1)
R2(R1-2.55)
4.3±0.5
14.75±0.1
13.2±1.0
0 240 500 750
400 475
0 400
250-40 (650) 1000 (1180) 1400
(1085) 1300
PUMP SPEED(r/min)
PUMP SPEED(r/min)

BOOST COMPENSATOR PERFORMANCE Pre-stroke(Pre-stroke output voltage)

CONTROL RACK POSITION(mm)

Solenoid starting advance

+0.03 angle
2.0 -0.10
N=400r/min

R2(R1-2.55) 3.04(b2)
3.24(b1) b(confirmation point)

3.44(a2)
3.70(a1) a(adjusting point)
R2-1.65 Minimum advance angle
adjustment stopper
3.87±0.03(C)
0
12.0±1.3 Approx. 30.7 Pre-stroke at stopper
contact
(90±10) (Approx. 230) 4.0±0.03
0 (800) 1,000 1,200

Pump speed (r/min)

BOOST PRESSURE kPa(mmHg)

Speed control lever angle Stop lever angle

Stopper bolt H position

Hole(R42) 45°±5°
Set the position
5° R=1.5±0.2,
22.5°± N=0
Idling

Normal Stop

23º
±3°
32º
±5° Full-speed
Hole(R41.3)
6C – 82 FUEL SYSTEM

4.2 Boost compensator adjustment

1) Select a push rod so C = 37.5 ± 0.5 at full boost
pressure. (C is the distance from the end face of the
housing to top of the lever.)
2) Adjust the boost compensator stroke using screw A.
(0 boost pressure position adjustment)
Adjust the beginning of boost compensator operation
by adjusting the notch adjusting nut B.

040L200003-X 4.3 Timing cam adjustment (Timing cam No: 510)

1) Hold speed control lever against full speed stopper
bolt.
2) Supply boost pressure of at least 44.0 kPa {at least
330 mmHg}
3) Operate pump at the timing cam adjusting point
(point a table below: Np = 1,000 r/min).
4) Perform timing cam adjustment so output voltage is
within range of a1 ∼ a2 actually measured for pore-
stroke output voltage during injection timing
adjustment in 3-4.

Output
Pre-stroke
Adjusting point voltage Remarks
(mm)
(actual)
3.70 a1 + tolerance
a
3.44 a2 - tolerance

5) Operate the pump at the timing cam confirmation

point
(point b in table below: Np = 1,200 r/min)
6) Confirm that the pre-stroke output voltage is within
the range b1 ∼ b2.

Output
Confirmation
Pre-stroke (mm) voltage Remarks
point
(actual)
3.24 b1 + tolerance
b
3.04 b2 - tolerance
 FUEL SYSTEM 6C – 83

5. Injection quantity

Max.
Rack Pump
Adjusting Injection q’ty variation Pre-stroke
position speed 3 Flxed Remarks
point (cm /1,000 strokes) between at adjustment
(mm) (r/min)
cylinders

Cylinder variation
- 16.1 1,000 124 ± 1.6 ±4 Rack a1 ∼ a2 (v) Basic
adjustment standard

Cylinder variation
Z 8.7±0.5 585 14 ± 1.5 ± 14 Rack c (v)
adjustment standard

Boost press. kPa {mmHg}

A R1 (16.1) 1,000 124 ± 1 - Lever a1 ∼ a2 (v) Basic
Above 44.0 {Above 330}

Boost press. kPa {mmHg}

B R1+0.45 1,150 123.5 ± 2 - Lever Mesure
Above 44.0 {Above 330}

Boost press. kPa {mmHg}

Above 44.0 {Above 330}
D* 16.15±0.1 1,150 - - Lever Mesure
Negative press. kPa {mmHg}
53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point

6. FICD Adjustment
1+1 mm
1) Stop the injection pump.
2) Hold speed control lever against idling stopper bolt.
2
3) Adjust clearance between FICD actuator lever and
+1
speed control lever to approx. 1 mm.
Speed control 4) Loosen nut ! and fully tighten FICD set bolt ".
lever
5) Apply 53.3 kPa {400 mmHg} negative pressure to
the actuator # and set the pump speed at 450
r/min.
FICD actuator lever 6) Gradually loosen set bolt " then fix bolt using nut
3
±0.1
Tightening torque when the rack position is 8.1 mm.
1 5~7N·m{0.5~0.7kgf·m}
7) Apply above negative pressure several times and
confirm FICD actuator is operating properly and
040L200006
clearance between FICD actuator lever and speed
control lever.

Stroke
7. Aneroid compensator actuator adjustment (injection
quantity decrease)
Rack position (mm)

NOTE:
Injection quantity decrease
Set this actuator after adjusting the full rack position.
adjustment point
1) Stop injection pump.
2) Adjust wire nut so full load set lever contacts full load
set bolt and aneroid compensator actuator wire is not
Pump speed (r/min)
loose. Then, fix the nut.
040L200007 3) Apply 53.3 kPa {400 mmHg} negative pressure to
aneroid compensator, set pump speed at 1,150
r/min.
6C – 84 FUEL SYSTEM

4) Apply at least 44.0 kPa {330 mmHg} boost pressure

to the boost compensator.
5) After operating full load set lever, adjust aneroid
compensator set bolt so control rack position is
A
16.15±0.1mm and fuel injection quantity is as specified.
B
Then, fix the set bolt.

Full load set lever

Full load set bolt

040L200008

8. Rack Sensor Adjustment

Rack position(mm)

R1
A 1) Before removing rack position measuring device,
apply at least 44.0 kPa {at least 330 mmHg} boost
pressure and confirm rack position is R1 = 16.1 mm
and fuel injection quantity is 124 ± 1 mm3/st at N =
1,000 r/min.
N 2) Remove the rack position measuring device.
Pump speed(r/min) 3) Attach the rack sensor core to the control rack.
040L200011
At this time, hold control rack using a spanner (to
prevent the rack from bending).
Specified torque: 3.4 ～ 4.9 N•m {0.35 ～ 0.5
kgf•m}
4) While pulling stop lever, install rack sensor to rack
Sensor output voltage(V)

sensor core.
Vist 5) Tighten the two flnge fixing screws.
Specified torque: 6.9 ～ 8.8 N•m {0.7 ～ 0.9 kgf•m}
6) Connect the rack sensor wire harness to constant
voltage power supply and digital voltmeter.
R1
7) Turn constant voltage power supply power switch ON
Rack position(mm) and set it to DC 5 ± 0.01V.
040L200012 8) Apply at least 44.0 kPa {at least 330 mmHg} boost
pressure, set pump speed at N = 1,000 r/min, and
hold speed control lever against the full speed
stopper bolt.
9) Confirm the rack sensor output voltage from the
digital voltmeter. (Vist = 2.77 ± 0.28)
10) Confirm that the voltage changes when the speed
control lever is moved to the idle and full sides.
 FUEL SYSTEM 6C – 85

FUEL TANK

6C-75-1.tif

REMOVAL
Preparation
• Disconnect the battery ground cable.
• Loosen the fuel filler cap.
• Drain fuel from drain plug.
• After the drain fuel, tighten the drain plug to the specified
torque.
N·m (kg·m/lb·ft)
29 (3/22)

1. Evapo Fuel Hose

2. Fuel Feed Hose
3. Fuel Return Hose
• Plugging the return hose to prevent fuel from getting
spilt, tie it to the fame with the plugged end up.
4. Fuel Gauge Unit Connector
• Remove the fuel gauge unit connector.
5. Band
• Remove the nut of the fuel tank fixing band, and then
remove the band end on the frame side.
6C – 86 FUEL SYSTEM

6. Fuel Tank
• Pull out the fuel tank to the outside.
NOTE:
When it is not possible to pull out the fuel tank,
remove the bracket and then draw out the fuel tank
downward.

INSTALLATION
6. Fuel Tank
NOTE:
When the bracket was removed to take off the fuel
tank, install the bracket to the frame and tighten it to
the specified torque.
N∙m (kg∙m/lb∙ft)
55 (5.6/41)

Also, when mounting the fuel tank to the bracket, place

the packing section attached to the fuel tank securely
on the bracket.
5. Band
• Tighten the band to the specified torque
N∙m (kg∙m/lb∙in)
12 (1.2/104)

4. Fuel Gauge Unit Connector

• Connect the fuel gauge unit connector.
3. Fuel Return Hose
2. Fuel Feed Hose
• Set the hose to the pipe more than 25mm deep.
1. Evapo Fuel Hose
• Fill the fuel to the fuel tank.
• Connect battery ground cable.
 FUEL SYSTEM 6C – 87

FUEL GAUGE UNIT

6C-77-1.tif

REMOVAL
Preparation: Disconnect the Battery ground cable.
1. Fuel Gauge Unit Connector
• Disconnect the fuel gauge unit connector from the fuel
gauge unit.
2. Fuel Gauge Unit
• Remove the fuel gauge unit fixing screw and fuel
gauge unit.
NOTE:
• After removing fuel gauge unit, cover fuel tank with
waste to prevent any dust entering

INSTALLATION
2. Fuel Gauge Unit
1. Fuel Gauge Unit Connector
• Connect the wiring connector to the fuel gauge unit.
6C – 88 FUEL SYSTEM

ACCELERATOR CONTROL
ACCELERATOR CONTROL CABLE

6C-78-1.tif

REMOVAL
1. Adjust Nut
• Loosen the adjust nut on the cable bracket mounted.
2. Accelerator Control Wire (Injection pump side)
• Remove the control wire from injection pump control
lever.
3. Accelerator Control Wire (Accelerator pedal side)
• Remove the Accelerator control wire from accelerator
pedal.
4. Accelerator Control Cable
• Pull out the wire to the chassis side through the
grommet hole of the floor board, and remove the
control cable.

INSPECTION
Check the following items, and replace the control cable if
any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should be free of damage and
corrosion.
 FUEL SYSTEM 6C – 89

INSTALLATION
5. Accelerator Control Cable
• Take care that the core wire of the cable does not get
damaged or inded.
• Put the cable through the grommet hole from under the
floor.
• Set the groove of the grommet securely into the floor
panel.
4. Accelerator Control Wire (Accelerator Pedal side)
• Connect the accelerator control wire to Accelerator
pedal.
3. Cable Clips
• Install the cable clip to chassis frame.
• Tighten the cable clips to the specified torque
N∙m (kg∙m/lb∙ft)
16 (1.6/12)

2. Accelerator Control Wire

1. Adjust Nut
• Attach the end tip of the wire to the engine control
lever.
• Pull the outer cable gently toward the front of the
vehicle, and provide the engine control wire and the
accelerator control wire an appropriate play before
fastening the clamp with a nut.
N∙m (kg∙m/lb∙in)
8 (0.8/69)

• Check to see if the injection pump lever is at the idle

position (with the lever in touch with the stopper bolt).
• Connect the battery ground cable.
• Check to see if the accelerator pedal fully is in the
range of 5 to 10mm above the pedal pad.
• Press down on the accelerator pedal fully, and check to
see if the engine rotates at the maximum speed with
the linkage in the smooth operation.
• In the operating range of the accelerator pedal, check
to see if the accelerator pedal and the injection pump
lever return without fail to the original positions.
6C – 90 FUEL SYSTEM

ACCELERATOR PEDAL

6C-80-1.tif

REMOVAL
1. Switch Connector
2. Accelerator Control Cable.
• Remove control cable from Accelerator pedal bracket.
3. Idling Control Cable
• Remove control cable from accelerator pedal bracket.
4. Accelerator Pedal Assembly
• Remove accelerator pedal assembly from brake pedal
bracket.

INSTALLATION
4. Accelerator Pedal Assembly
• Apply grease to the sliding portion, and install it to the
brake pedal bracket.
3. Idling Control Cable
• Install the idling control cable to the lever of the
accelerator pedal bracket.
2. Accelerator Control Cable
• After confirming that the idling control knob is turned
fully to the left, install the accelerator control cable.
1. Switch Connector

6C-80-2.tif
 FUEL SYSTEM 6C – 91

IDLING CONTROL CABLE

6C-81-1.tif

REMOVAL
1. Idling Control Knob
• Loosen the idling control knob screw and remove the
knob from cable.
2. Idling Control Cable Nut
3. Wave Washer
4. Idling Control Cable
• Remove control cable from accelerator pedal bracket.

INSTALLATION
4. Idling Control Cable
• Install control cable to Accelerator pedal bracket.
3. Wave Washer
2. Idling Control Cable Nut
• Insert the idling control cable into the specified hole of
the instrument panel.
• Install the washer to the cable, and tighten it with a nut.
6C – 92 FUEL SYSTEM

1. Idling Control Knob

• Insert the idling control knob into the cable, and tighten
the screw.

Inspection:
• With the idling control knob not in use, check to see if
the injection pump lever is at the idle position (with the
lever in contact with the stopper bolt).
• With the idling control knob turned fully to the right,
check to see if the number of the engine idling rotations
gets to 1,500 rpm or more.
 FUEL SYSTEM 6C – 93

AIR CLEANER ELEMENT

6C-83-1.tif

REMOVAL
1. Cover Wing Nut
2. End Cover
3. Filter Wing Nut
4. Air Cleaner Element

Clean
• Wipe out the inside of the Air cleaner assembly
• Wipe off the Cover

Inspection
• The air filter with a light for fears or holes.

6C-83-2.tif

Cleaning Method
Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
2
Compressed air pressure Kpa (Kg/cm /Psi)
392 - 490 (4 - 5/57 - 71)

6C-83-3.tif CAUTION
Do not bang the element against another object in an
attempt to clean it. Damage to the element will result.
6C – 94 FUEL SYSTEM

Carbon and Dust Fouled Element

1. Prepare a cleaning solution of Isuzu Genuine Element
Cleaner (Donaldson D1400) diluted with water.
2. Submerge the element in the solution for twenty
minutes.

6C-84-1.tif

3. Remove the element from the solution and rinse it well

with running water.
Water pressure must not exceed 274 Kpa (2.8
2
kg/cm /40 Psi)

6C-84-2.tif

4. Dry the element in a well ventilated area.

An electric fan will hasten drying.
NOTE:
Do not use compressed air or an open flame to dry the
element quickly. Damage to the element will result.
It will usually take two or three days for the element to
dry completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.

6C-84-3.tif

INSTALLATION
4. Air Cleaner Element
3. Filter Wing Nut
2. End Cover
1. Cover Wing Nut