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ENGINE FUEL 6C – 1

ENGINE FUEL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . 6C–1 High Pressure Oil Pump . . . . . . . . . . . . . 6C–15
On-Vehicle Service . . . . . . . . . . . . . . . . . . 6C–7 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 6C–20
Fuel Filter Assembly . . . . . . . . . . . . . . . . 6C–7 Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . 6C–21
Fuel Filter Cartridge . . . . . . . . . . . . . . . . 6C–7 Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . 6C–21
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–9
Fuel Pump Pipe . . . . . . . . . . . . . . . . . . . 6C–13

GENERAL DESCRIPTION
To realize the compatibility between low exhaust When working on the fuel system, there are several
emission and high engine output, an HEUI things to keep in mind:
(Hydraulically actuated Electronically controlled Unit 1) Any time the fuel system is being worked on,
Injector) system, has been introduced. This system is disconnect the negative battery cable except for
comprised of a hydraulic system, fuel system, and those tests where battery voltage is required.
electronic control system, using a high-pressure oil
2) Always keep a dry chemical (Class B) fire
pump in place of the conventional fuel injection pump.
extinguisher near the work area.
The oil pressurized by means of this pump and by
signals from the ECM (Electronic Control Module) 3) Replace all pipes with the same pipe and fittings
actuates the fuel injector provided for each cylinder. that were removed.
Inside of the fuel injector, fuel pressure is increased due Clean and inspect “O” rings. Replace where
to the high-pressure oil. The ECM detects the driving required.
state of the vehicle, forms, signals sent by engine and 4) Always relieve the line pressure before servicing
other part sensors, which determines the optimum fuel any fuel system components.
injection amount and timing, thus controlling the fuel 5) Do not attempt repairs on the fuel system until you
injectors. Thus high engine output, good fuel economy, have read the instructions and checked the pictures
and low exhaust emission are realized. relating to that repair.
6) After maintenance work, push priming pump and
send enough fuel to the fuel system before starting
the engine.
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.
6C – 2 ENGINE FUEL

FUEL FLOW

For Europe, Nicaragua, 1


9 Argentina, Philippin
8 10 11 14

2
12

3
13

7 6 4

5 Except above region 1

11 14

040R200001

Legend (8) Cylinder Head


(1) Fuel Filler Cap (9) Injector
(2) Fuel Tank (10) Orifice
(3) Rollover Valve (11) Fuel Return Pipe
(4) Fuel Supply Pipe (12) Fuel Tank Pressure Release Hose
(5) Fuel Filter with Priming Pump (13) Intake Air Duct
(6) Fuel Pump (14) Fuel Tank Pressure Control Valve
(7) High Pressure Oil Pump
ENGINE FUEL 6C – 3

FUEL PUMP

4
3

140RW041

Legend (3) From Fuel Tank


(1) High Pressure Oil Pump (4) Fuel Pump
(2) To Injector
6C – 4 ENGINE FUEL

HIGH PRESSURE OIL PUMP, OIL FLOW


1

3 4 6

5 7

33

32
8
31

9
30

29
10

11
13 12
23
14
25 15
16
24
••

28 26
27

18 17
22 21 20 19
040RW018

Legend (17) Oil Pan


(1) Camshaft (18) To Oil Pan
(2) Balance Shaft (19) Balance Shaft
(3) Crankshaft (20) Cooling Jet Relief Valve 245 Kpa (2.5 kg/cm2/
(4) Oil Cooler and Oil Filter Assembly 36 Psi)
(5) Oil Filter Relief Valve 98 Kpa (1 kg/cm2/14.2 Psi) (21) Cooling Jet
(6) Oil Cooler Relief Valve 245 Kpa (2.5 kg/cm2/ (22) To Oil Pan
36 Psi) (23) Two Way Check Valve
(7) First Oil Pump (24) Nipple Filter
(8) Main Oil Relief Valve 588 Kpa (6 kg/cm2/ 85 Psi) (25) Edge Filter
(9) To Oil Pan (26) Edge Filter
(10) To Oil Pan (27) High Pressure Oil Pump Assembly
(11) Injector (28) To Oil Pan
(12) Oil Rail (29) Pressure Control Valve
(13) Sub Oil Filter Relief Valve 98 Kpa (1 kg/cm2/ (30) To Oil Pan
14.2 Psi) (31) Turbocharger
(14) Sub Oil Filter (32) Oil Gallery
(15) Relief Valve 588 Kpa (6 kg/cm2/ 85 Psi) (33) Timing Gear Train
(16) Second Oil Pump
ENGINE FUEL 6C – 5

FUEL FILTER INJECTOR ASSEMBLY

041RW017

Legend
(1) Priming Pump
(2) Fuel Filter Cartridge

2
A cartridge type fuel filter is used along with the piston
type fuel pump on the high pressure oil pump.
The fuel filter removes foreign material from the fuel
before it reaches the fuel pump.
A diaphragm type priming pump is installed at the top of
the fuel filter. It is used during the air bleeding
procedures.

055RW018

Legend
(1) Oil Passage
(2) Fuel Passage

1. Construction of Fuel Injector


The fuel injector is comprised of the solenoid
section, hydraulic line, and fuel line. Fuel injection is
controlled by the continuity time signal and
continuity start timing signal sent by the ECM
(Electronic Control Module) to the solenoid.
2. Working of Fuel Injector
1) The ECM detects the working of the engine from
its input signals, such as engine speed
accelerator throttle opening, and engine coolant
temperature, sending the optimal signals to the
solenoid.
6C – 6 ENGINE FUEL

2) With the current carried to the solenoid, a


poppet valve is opened by means of an
armature to let high-pressure engine oil into the
injector.
3) Under the oil pressure, the piston and plunger
are depressed to compress the fuel. The
pressure of the compressed fuel is increased
over the pressure of high-pressure engine oil by
the ratio (about 7 : 1) of piston top to plunger
bottom.
4) The injection nozzle end needle is lifted under
the increased pressure of the fuel for fuel
injection.
5) With current stopped from the ECM, the poppet
valve is closed which holds up the high-pressure
engine oil and lets the oil used to compress fuel
out of the injector through its drain hole.
ENGINE FUEL 6C – 7

ON-VEHICLE SERVICE
FUEL FILTER ASSEMBLY

012RW111

Legend
(1) Priming Pump

REMOVAL FUEL FILTER CARTRIDGE


1. Disconnect battery ground cable.
2. Fuel Filler cap
DISASSEMBLY
3. Fuel Hose 1. Drain fuel completely from the fuel filter.
1) Disconnect fuel hose from filter body. 2. Protect the filter body with cloth and lightly grip with
Plug the hose ends to prevent fuel spillage. a vise.
4. Remove the Bolt on Fuel Filter Bracket 3. Remove the cartridge using a filter wrench.
5. Remove Fuel Filter Assembly Filter wrench: 5-8840-0203-0

INSTALLATION
1. Install the fuel filter assembly
2. Tighten the Fuel Filter Bracket Fixing Bolt
3. Fuel Hose
1) Connect hoses to filter body.
4. Fuel Filler Cap
1) Connect the battery ground cable.
2) Feed fuel to the fuel pump by priming, and bleed
the air from fuel system.

012RW112
6C – 8 ENGINE FUEL

REASSEMBLY Bleeding
1. Clean the cartridge mounting surface of the filter 1. Loosen air bleeding plug.
body so that the cartridge can be secured. 2. Operate priming pump to bleed the air in the fuel
Apply engine oil thinly to new cartridge O-ring. line.
2. To facilitate bleeding, fill the new cartridge with light 3. Operate the priming pump until the fuel is overflow
oil. from air bleeding plug.
3. Tighten the cartridge until O-ring comes in contact 4. Tighten the air bleeding plug.
with the seal, taking care not to spill the light oil. 5. Start the engine, and if it is not started in 10
4. Retighten 1/3 – 2/3 using a filter wrench. seconds or less, repeat the bleeding steps.
Filter wrench: 5-8840-0203-0 6. Make sure of no fuel leakage, and tighten the
priming pump.

012RW078

012RW111

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.
ENGINE FUEL 6C – 9

INJECTOR

4
5

With
7 spacer type

6
9

Without
spacer type

012R200006

Legend (8) Gasket


(1) Nut and Washer (9) O-Ring
(2) Injector Clamp
(3) Nut
(4) Bolt
(5) Oil Rail Assembly
(6) Spacer (If equipped) and Bolt
(7) Injector Assembly
6C – 10 ENGINE FUEL

REMOVAL 2 1
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. 4

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
3
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. 055RW00001

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


(1) Part Number
NOTE: Cloth should be put around the loosened eye (2) Category Number (Grade code)
bolt to prevent fuel from flowing out. (3) Serial Number
8. Remove fuel return hose at chassis side. (4) Bar Code
9. Remove PCV hose to cylinder head cover.
10. Remove cylinder head cover. 13. Remove harness connector from each injector.
11. Drain the oil from oil rail assembly. 14. Loosen nuts and bolts for oil rail.
NOTE: Do not drop O-ring 15. Remove injector fixing bolts.
16. Remove injector clamp.
12. Record the grade code of injector for each cylinder
that is indicated on the upper portion of injector. 17. Remove injector assembly.
There are nine kinds of grade code available, one
alphabet letter and one numeral letter.
INSTALLATION
Grade code 1. Install oil rail, tighten temporarily
Category number 2. Install injector assembly.
A–1 NOTE:
A–2 1) Do not forget to install O-ring between injector and
A–3 oil rail.
B–1 2) Use new O-ring
B–2 3) Clean O-ring groove and fitting surface of parts.
B–3 4) Apply engine oil to O-ring.
C–1 3. Install injector fixing bolts, tighten temporarily.
C–2 4. Install injector clamp, tighten nut temporarily.
C–3 5. Tighten injector fixing bolts to the specified torque.
Torque: 6.5 N·m (0.7 kg·m / 5.1 lb ft)
6. Tighten injector clamp nut to the specified torque
with special method.
Torque: 30 N·m (3.1 kg·m / 22.4 lb ft) then loosen a
time again tighten as following torque.
Torque: 25 N·m (2.4 kg·m / 17.4 lb ft)
7. Tighten oil rail to the specified torque.
Torque: 20 N·m (2.0 kg·m / 14.5 lb ft)
ENGINE FUEL 6C – 11

8. Install injector harness assembly, reconnect NOTE:


harness connecter to injector. 1) On completion of servicing, bleed air from the
9. Record the identification marking of injector for engine inside fuel passage by means of the priming
each cylinder that is indicated on the upper portion pump. (The priming pump should be operated more
of injector. times than in the case of conventional engines.)
2) As air is in the oil rail, it takes more time to start the
2 1 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.
4
Injector Grade code Programming
(Injector Change)
In case of an injector change, the injector grade code
(category number) must be programmed by Tech-2.
3
Programming Procedure
1. Connect the Tech-2 to the vehicle DLC.
2. Turn the starter switch to the “ON” position.
055RW00001
3. Select the “Diagnosis” from the Main menu.
Legend 4. Select the “Programming” from the Application
(1) Part Number menu.
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code

• • • ••• • ••• • •• • • • • • • • • • • • • • • • • • • •
10. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
F0 : • •• • • • • ••• •• • • • • • • • • • • • • • • • • • •
11. Fill with about 300cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler. F1 : • • •• •• •• • •• • • • • • • • • • • • • •
If assembled without filling the oil rail with oil, the
time for engine starting will be longer. F2 : • • • • • • • •••••••••
12. Immediately install high pressure oil pipe and
tighten to specified torque. F3 : • •• • • ••• • • • • • •• • • •••••••••••••••••••
Torque: 80 N·m (8.1 kg·m / 57.9 lb ft)
13. Install cylinder head noise insulator cover. F4 : • •• • •• • • •• • • • • • • • • • • • •
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. 035RW00002

For rewriting method refer to section “Data


Programming in Case of ECM Change” of section
6E 4JX1 engine driveability and emissions in this
manual.
6C – 12 ENGINE FUEL

5. Select “Programming Trim Date” from 9. Confirm the completion of injector programming.
Programming menu.
6. Select the injector change from Programming Trim
Date menu.
7. Select the cylinder number which changed injector. • •• • •• • • •• • •• ••• •• • •• • • • • • • • • • • • • • • • • • • • • •
(W) 1998 (UE) Rodeo/Amigo,Wizard
• •• • ••• • •• •• • • •• • • •3.0L
• •L4• 4JX1
• • • • • • • • • • • • • •

Programming Trim Data


(W) 1998 (UE) Rodeo/Amigo,Wizard •• •• • •• •• •1 • • • • • • • • Category A1
Electronic System• 3
• .0L L4 4JX1
• •• • •• • • •• • •• • • •• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Injector• 1

Injector• 2

Injector• 3

Injector• 4

Injector• 1
• • • • •••• • • • • • • • • • • •

035RW00005

Select cylinder Note; The injector grade code (category number) is


indicated on the new (service part) injector.
035RW00003

8. Appoint and select the grade code (Category


number) of injector.

Programming Trim Data


(W) 1998 (UE) Rodeo/Amigo,Wizard
Electronic System• 3
• .0L L4 4JX1

Injector• 1

Do you program trim data in


this cylinder• •••

No Yes

035RW00004
ENGINE FUEL 6C – 13

FUEL PUMP PIPE

10
8

040R200002

Legend
(1) Cap Nut (6) Gasket
(2) Gasket (7) Fuel Pump Pipe
(3) Gasket (8) Eye Bolt
(4) Pipe Nut (9) Gasket
(5) Adapter (10) Gasket

REMOVAL INSTALLATION
1. Remove eye bolt. 1. Apply engine oil to the thread, then install adapter
2. Remove cap nut. with new gasket.
NOTE: The eye bolt and cap nut should be Torque : 16 N·m (1.6 kg·m/12 lb ft)
disconnected with cloth tied around them to prevent NOTE: Be careful not to enter the foreign material.
flowing out of fuel.
3. Remove fuel pump pipe. 2. Apply engine oil to the thread, then install pipe nut.
4. Remove pipe nut.
Torque : 10 N·m (1.0 kg·m/87 lb ft)
5. Remove adapter.
NOTE: Do not apply oil to cap nut side.

3. Install fuel pump pipe, new gaskets and cap nut to


adapter temporarily. Do not tighten the cap nut.
4. Install eye bolt with new gasket then tighten to
specified torque.
Torque : 29 N·m (3.0 kg·m/22 lb ft)
6C – 14 ENGINE FUEL

NOTE:
1) Do not apply oil to the eye bolt.
2) Do not bend the fuel pump pipe.

5. Tifhten cap nut to specified torque.


Torque : 13 N·m (1.3 kg·m/113 lb ft)
NOTE: Do not apply oil to the cap nut.

6. Start the engine, check that the fuel leakage is not


found.
ENGINE FUEL 6C – 15

HIGH PRESSURE OIL PUMP


3
2

040RW007

Legend
(1) O-Ring
(2) High Pressure Oil Pump Assembly
(3) Nut
(4) O-Ring

REMOVAL
1 4
1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct
3. Intercooler assembly 2
Refer to “Intercooler” in this manual.
4. Remove high pressure oil pipe
5. Timing belt cover
3
Disconnect CMP sensor cable.
Remove CMP sensor bracket.
6. Tensioner
7. Timing Belt
8. Remove high pressure oil pump timing pulley
9. Remove crankshaft damper pulley
10. Remove timing gear case cover
11. Remove idle gear A
Before removing idle gear A, set two bolts to the
sub gear of idle gear A and turn it to align the teeth 014RW177
of idle gear A main gear.
Legend
Then lock them by bolts as shown in the illustration. (1) Idle gear A sub gear
(2) Idle gear A main gear
(3) Bar
(4) Lock bolt
6C – 16 ENGINE FUEL

12. Remove high pressure oil pump


3
13. Remove high pressure oil pump assembly 2

040RW007

Legend
(1) O-ring
(2) High pressure oil pump
(3) Nut
(4) O-ring
ENGINE FUEL 6C – 17

INSPECTION AND REPAIR


The high pressure oil pump is made precisely,
therefore, disassembly is not recommended.

INSTALLATION
1. Set O-ring to high pressure oil pump assembly.
Install the pump assembly into the rear of timing
gear case. 1
Tighten nut to specified torque.
Torque: 20 N·m (2.0 kg·m/14.5 lb ft)

3
2
2
1
3
4
040RW006

Legend
(1) High Pressure Oil Pump Assembly
(2) Nut
(3) Two Way Valve Bracket
(4) Bolt

4
3. Install the pump gear to align timing mark with idle
gear A.
Tighten high pressure pump gear fixing bolt to the
specified torque.
Apply engine oil to thread and seat of bolt.
Torque: 75 N·m (7.6 kg·m/55 lb ft)
040RW007

Legend
(1) O-ring
(2) High Pressure Oil Pump Assembly GEAR:O/PUMP 4
(3) Nuts
(4) O-ring

2. Tighten high pressure oil pump assembly bracket IDLE GEAR A


together with two way valve bracket.
Torque: 27 N·m (2.8 kg·m/20.2 lb ft)
1
2
3

040RW005

Legend
(1) O-ring
(2) Pump Gear
(3) Bolt
(4) Timing Mark
6C – 18 ENGINE FUEL

4. Remove lock bolt of idle gear A. 14. Install the crankshaft damper pulley with specified
5. Install timing gear case cover. torque.
Refer to “Timing gear” in this manual. Torque: 220 N·m (22 kg·m/159 lb ft)
6. Install front plate. 15. Install the intercooler assembly.
Torque: 20 N·m (2.0 kg·m/14.5 lb ft) Refer to “Intercooler” in this manual.
7. Install timing pulley of high pressure oil pump. 16. Install air cleaner cover and air duct.
Torque: 10 N·m (1.0 kg·m/7.2 lb ft)
8. Install timing belt and tighten timing belt tensioner
assembly.
Refer to “Cylinder head” in this manual.

8 7

6
5
4

F06RW055

Legend
(1) Align Mark
(2) Camshaft Pulley
(3) Timing Belt
(4) High Pressure Oil Pump Pulley
(5) Bolt
(6) Tensioner Assembly
(7) Tensioner Bolt
(8) Tensioner Spring

9. Install CMP sensor bracket.


Torque: 20 N·m (2.0 kg·m/14.5 lb ft)
10. Connect CMP sensor cable.
11. Install timing belt cover.
Torque: 9 N·m (0.9 kg·m/6.5 lb ft)
12. Fill with about 300 cc 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.
13. Immediately install high pressure oil pipe and
tighten to specified torque.
NOTE:
1) Use new O-ring.
2) Clean O-ring groove and fitting surface of parts.
3) Apply engine oil to O-ring.
Torque: 80 N·m (8.1 kg·m/57.9 lb ft)
ENGINE FUEL 6C – 19

HIGH PRESSURE OIL PIPE INSTALLATION

10

2
4

8 5

11

052R200001

Legend (7) Pipe A


(1) Union Nut F (8) Union Nut C
(2) Pipe B (9) Lower Bracket
(3) Union Nut E (10) To Oil Rail
(4) Upper Bracket (11) To High Pressure Oil Pump
(5) Two Way Valve
(6) Union Nut D

1. Install upper bracket to two way valve, tighten them


temporarily.
2. Install pipe A to two way valve, tighten pipe A
temporarily with union nut D.
3. Install two way valve assembly to cylinder block,
tighgten with union nut C temporarily.
4. Install pipe B to two way valve, tighten union nut E
and union nut F temporarily.
5. Tighten upper bracket to specified torque.
Torque : 20 N·m (2.0 kg·m/14.5 lb ft)
6. Tighten union nut in the following order, union nut
C, D, F, and E to the specified torque.
Torque : 80 N·m (8.1 kg·m/57.9 lb ft)
7. Tighten lower bracket to the specified torque.
Torque : 20 N·m (2.0 kg·m/14.5 lb ft)
NOTE: Wash inside pipe, inside union nut and O-ring
seal surface to remove engine oil and foreign materials.
6C – 20 ENGINE FUEL

FUEL TANK

Europe, Nicaragua, Argentina, Philippin


8
1
6

7
8
2
3

4
6

140R200032

Legend (4) Under Cover


(1) Fuel Tank Assembly (5) Bolt
(2) Gauge Unit (6) Fuel Filler Hose
(3) Bolt (7) Fuel Filler Cap
(8) Breather Hose

REMOVAL INSTALLATION
1. Disconnect battery ground cable. 1. Fuel tank assembly.
2. Remove fuel filler cap. 1) Place a flange on right side of tank on the
3. Drain fuel. bracket.
After drain the fuel tighten the drain plug with 2) Install a flange to left side of the bracket from the
specified torque. bottom, and tighten bolts to the specified torque.
Torque : 20 N·m (2.0 kg·m/14 lb ft) Torque : 36 N·m (3.7 kg·m/26.8 lb ft)
4. Remove fuel filler hose and let air pull off hose. 2. Install fuel hose and fuel return hose.
5. Remove breather hose. 3. Install the breather hose.
6. Remove fuel feed hose and fuel return hose. 4. Reconnect harness connector to fuel gauge unit.
7. Disconnect harness connector from fuel gauge unit. 5. Install under cover.
8. Remove under cover. 6. Install fuel filler hose and let air pull off hose.
9. Remove fuel tank assembly. 7. Fill fuel tank with fuel and tighten filler cap.
8. Reconnect battery ground cable.
ENGINE FUEL 6C – 21

FUEL GAUGE UNIT

140R200033

Legend
(1) Fuel Tank Assembly
(2) Fuel Gauge Unit
(3) Drain Plug

REMOVAL
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
After drain the fuel tighten the drain plug with
specified torque. 3
Torque : 20 N·m (2.0 kg·m/14 lb ft)
4. Disconnect harness connector from fuel gauge unit.
5. Fuel Gauge Unit
1) Remove the fixing screws, then the fuel gauge
1
unit.

INSTALLATION 2
1. Fuel Gauge Unit
2. Connect the harness connector to the fuel gage
unit.
3. Fill the tank with fuel and tighten fuel filler cap. 060R200247

4. Connect battery ground cable. Legend


(1) Vacuum Valve
FUEL FILLER CAP (2) Pressure Valve
The fuel filler cap contains a vacuum valve. If a (3) Seal Ring
negative pressure develops in the fuel tank, the
external valve of the fuel filler cap opens to allow the
fresh air to flow into the fuel tank through the vacuum
valve.

INSPECTION
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
MEMO