jackaroo ubs-73 workshop manual -...

ENGINE FUEL 6C – 1

ENGINE FUELCONTENTS

GENERAL DESCRIPTION

General Description . . . . . . . . . . . . . . . . . . 6C–1

On-Vehicle Service . . . . . . . . . . . . . . . . . . 6C–7

Fuel Filter Assembly . . . . . . . . . . . . . . . . 6C–7

Fuel Filter Cartridge . . . . . . . . . . . . . . . . 6C–7

Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–9

Fuel Pump Pipe . . . . . . . . . . . . . . . . . . . 6C–13

High Pressure Oil Pump . . . . . . . . . . . . . 6C–15

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 6C–20

Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . 6C–21

Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . 6C–21

To realize the compatibility between low exhaustemission and high engine output, an HEUI(Hydraulically actuated Electronically controlled UnitInjector) system, has been introduced. This system iscomprised of a hydraulic system, fuel system, andelectronic control system, using a high-pressure oilpump in place of the conventional fuel injection pump.The oil pressurized by means of this pump and bysignals from the ECM (Electronic Control Module)actuates the fuel injector provided for each cylinder.Inside of the fuel injector, fuel pressure is increased dueto the high-pressure oil. The ECM detects the drivingstate of the vehicle, forms, signals sent by engine andother part sensors, which determines the optimum fuelinjection amount and timing, thus controlling the fuelinjectors. Thus high engine output, good fuel economy,and low exhaust emission are realized.

When working on the fuel system, there are several

things to keep in mind:

1) Any time the fuel system is being worked on,disconnect the negative battery cable except forthose tests where battery voltage is required.

2) Always keep a dry chemical (Class B) fireextinguisher near the work area.

3) Replace all pipes with the same pipe and fittingsthat were removed.

Clean and inspect “O” rings. Replace whererequired.

4) Always relieve the line pressure before servicingany fuel system components.

5) Do not attempt repairs on the fuel system until youhave read the instructions and checked the picturesrelating to that repair.

6) After maintenance work, push priming pump andsend enough fuel to the fuel system before startingthe engine.

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

6C – 2 ENGINE FUEL

FUEL FLOW

1

14

Except above region

8 910 11

1

2

2

4

12

5

67

3

13

14

For Europe, Nicaragua,

Argentina, Philippin

11

4

Legend

(1) Fuel Filler Cap

(2) Fuel Tank

(3) Rollover Valve

(4) Fuel Supply Pipe

(5) Fuel Filter with Priming Pump

(6) Fuel Pump

(7) High Pressure Oil Pump

(8) Cylinder Head

(9) Injector

(10) Orifice

(11) Fuel Return Pipe

(12) Fuel Tank Pressure Release Hose

(13) Intake Air Duct

(14) Fuel Tank Pressure Control Valve

040R200001


FUEL PUMP

1

2

3

4

Legend

(1) High Pressure Oil Pump

(2) To Injector

(3) From Fuel Tank

(4) Fuel Pump

140RW041


HIGH PRESSURE OIL PUMP, OIL FLOW

• •

33

32

31

30

1

2

3 4

5

6

8

9

7

10

11

121314

23

29

25

28

27

26

24

1516

171819202122

Legend

(1) Camshaft

(2) Balance Shaft

(3) Crankshaft

(4) Oil Cooler and Oil Filter Assembly

(5) Oil Filter Relief Valve 98 Kpa (1 kg/cm2/14.2 Psi)

(6) Oil Cooler Relief Valve 245 Kpa (2.5 kg/cm2/

36 Psi)

(7) First Oil Pump

(8) Main Oil Relief Valve 588 Kpa (6 kg/cm2/ 85 Psi)

(9) To Oil Pan

(10) To Oil Pan

(11) Injector

(12) Oil Rail

(13) Sub Oil Filter Relief Valve 98 Kpa (1 kg/cm2/

14.2 Psi)

(14) Sub Oil Filter

(15) Relief Valve 588 Kpa (6 kg/cm2/ 85 Psi)

(16) Second Oil Pump

(17) Oil Pan

(18) To Oil Pan

(19) Balance Shaft

(20) Cooling Jet Relief Valve 245 Kpa (2.5 kg/cm2/

36 Psi)

(21) Cooling Jet

(22) To Oil Pan

(23) Two Way Check Valve

(24) Nipple Filter

(25) Edge Filter

(26) Edge Filter

(27) High Pressure Oil Pump Assembly

(28) To Oil Pan

(29) Pressure Control Valve

(30) To Oil Pan

(31) Turbocharger

(32) Oil Gallery

(33) Timing Gear Train

040RW018


FUEL FILTER

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

A cartridge type fuel filter is used along with the pistontype fuel pump on the high pressure oil pump.The fuel filter removes foreign material from the fuelbefore it reaches the fuel pump.A diaphragm type priming pump is installed at the top ofthe fuel filter. It is used during the air bleedingprocedures.

INJECTOR ASSEMBLY

Legend(1) Oil Passage(2) Fuel Passage

1. Construction of Fuel Injector

The fuel injector is comprised of the solenoidsection, hydraulic line, and fuel line. Fuel injection iscontrolled by the continuity time signal andcontinuity 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 fromits input signals, such as engine speedaccelerator throttle opening, and engine coolanttemperature, sending the optimal signals to thesolenoid.

1

2

041RW017

1

2

055RW018


2) With the current carried to the solenoid, apoppet valve is opened by means of anarmature to let high-pressure engine oil into theinjector.

3) Under the oil pressure, the piston and plungerare depressed to compress the fuel. Thepressure of the compressed fuel is increasedover the pressure of high-pressure engine oil bythe ratio (about 7 : 1) of piston top to plungerbottom.

4) The injection nozzle end needle is lifted underthe increased pressure of the fuel for fuelinjection.

5) With current stopped from the ECM, the poppetvalve is closed which holds up the high-pressureengine oil and lets the oil used to compress fuelout of the injector through its drain hole.


ON-VEHICLE SERVICE

FUEL FILTER ASSEMBLY

REMOVAL

1. Disconnect battery ground cable.

2. Fuel Filler cap

3. Fuel Hose

1) Disconnect fuel hose from filter body.

Plug the hose ends to prevent fuel spillage.

4. Remove the Bolt on Fuel Filter Bracket

5. Remove Fuel Filter Assembly

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 bleedthe air from fuel system.

FUEL FILTER CARTRIDGE

DISASSEMBLY

1. Drain fuel completely from the fuel filter.

2. Protect the filter body with cloth and lightly grip witha vise.

3. Remove the cartridge using a filter wrench.

Filter wrench: 5-8840-0203-0

1

Legend

(1) Priming Pump

012RW111

012RW112


REASSEMBLY

1. Clean the cartridge mounting surface of the filterbody 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 lightoil.

3. Tighten the cartridge until O-ring comes in contactwith 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 fuelline.

3. Operate the priming pump until the fuel is overflowfrom air bleeding plug.

4. Tighten the air bleeding plug.

5. Start the engine, and if it is not started in 10seconds or less, repeat the bleeding steps.

6. Make sure of no fuel leakage, and tighten thepriming pump.

Legend(1) Priming Pump

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

012RW078

1

012RW111


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


REMOVAL

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


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 tiedaround to prevent oil from spurting due to theremaining pressure.

2) High oil pressure pipe should be disconnectedwith cloth tied around the intake manifold glowplug to prevent oil from flowing out of the oilrail.

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

NOTE: Cloth should be put around the loosened eyebolt 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 cylinderthat is indicated on the upper portion of injector.There are nine kinds of grade code available, onealphabet 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 andoil 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.

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 torquewith special method.

Torque: 30 N·m (3.1 kg·m / 22.4 lb ft) then loosen atime 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.


1

4

3

2

055RW00001

Category number

A – 1

A – 2

A – 3

B – 1

B – 2

B – 3

C – 1

C – 2

C – 3


8. Install injector harness assembly, reconnectharness connecter to injector.

9. Record the identification marking of injector foreach cylinder that is indicated on the upper portionof 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 highpressure oil pipe installation port of the oil rail usingan oil filler.If assembled without filling the oil rail with oil, thetime for engine starting will be longer.

12. Immediately install high pressure oil pipe andtighten to specified torque.


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 “DataProgramming in Case of ECM Change” of section6E 4JX1 engine driveability and emissions in thismanual.

NOTE:

1) On completion of servicing, bleed air from theengine inside fuel passage by means of the primingpump. (The priming pump should be operated moretimes than in the case of conventional engines.)

2) As air is in the oil rail, it takes more time to start theengine. Rough idling may occur while the air isbeing bled completely after engine start, but it doesnot indicate trouble.

The air will be bled and normal engine status will bereached while the vehicle is driven for about 5 kmor engine is operated for about 5 minutes at 1500 to2000 rpm.

3) The injector spare part will be provided for groupnumber 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 Applicationmenu.

1

4

3

2

055RW00001

F0 : • •• • • • • ••• •• • • • • • • • • • • • • • • • • • •

F1 : • • •• •• •• • •• • • • • • • • • • • • • •

F2 : • • • • • • • •••••••••

F3 : • •• • • ••• • • • • • •• • • •••••••••••••••••••

F4 : • •• • •• • • •• • • • • • • • • • • • •

• • • ••• • ••• • •• • • • • • • • • • • • • • • • • • • •

035RW00002


5. Select “Programming Trim Date” fromProgramming menu.

6. Select the injector change from Programming TrimDate menu.

7. Select the cylinder number which changed injector.

8. Appoint and select the grade code (Categorynumber) of injector.

9. Confirm the completion of injector programming.

Note; The injector grade code (category number) isindicated on the new (service part) injector.

Injector• •1

Injector• •4

Injector• •3

Injector• •1

Programming Trim Data

Select cylinder

Injector• •2

(W) 1998 (UE) Rodeo/Amigo,Wizard

Electronic System• •3.0L L4 4JX1

035RW00003

Injector• •1

Programming Trim Data

Do you program trim data in

this cylinder• •••


Electronic System• •3.0L L4 4JX1

YesNo

035RW00004

•• •• • •• •• • • • • • • • • •1

• •• • •• • • •• • •• ••• •• • •• • • • • • • • • • • • • • • • • • • • • •

• •• • •• • • •• • •• • • •• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Category A1


• •• • ••• • •• •• • • •• • • • • • • • • • • • • • • • • • • • •3.0L L4 4JX1

• • • •••• • • • • • • • • • • •

035RW00005


FUEL PUMP PIPE

6

2

3

10

9

8

5

4

7

1

Legend

(1) Cap Nut

(2) Gasket

(3) Gasket

(4) Pipe Nut

(5) Adapter

(6) Gasket

(7) Fuel Pump Pipe

(8) Eye Bolt

(9) Gasket

(10) Gasket

040R200002

REMOVAL

1. Remove eye bolt.

2. Remove cap nut.

NOTE: The eye bolt and cap nut should bedisconnected with cloth tied around them to preventflowing out of fuel.

3. Remove fuel pump pipe.

4. Remove pipe nut.

5. Remove adapter.

INSTALLATION

1. Apply engine oil to the thread, then install adapterwith new gasket.

Torque : 16 N·m (1.6 kg·m/12 lb ft)

NOTE: Be careful not to enter the foreign material.

2. Apply engine oil to the thread, then install pipe nut.


NOTE: Do not apply oil to cap nut side.

3. Install fuel pump pipe, new gaskets and cap nut toadapter temporarily. Do not tighten the cap nut.

4. Install eye bolt with new gasket then tighten tospecified torque.



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.


NOTE: Do not apply oil to the cap nut.

6. Start the engine, check that the fuel leakage is notfound.


HIGH PRESSURE OIL PUMP

REMOVAL


2. Remove air cleaner cover and air duct

3. Intercooler assembly

Refer to “Intercooler” in this manual.

4. Remove high pressure oil pipe

5. Timing belt cover

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 thesub gear of idle gear A and turn it to align the teethof idle gear A main gear.

Then lock them by bolts as shown in the illustration.Legend

(1) Idle gear A sub gear(2) Idle gear A main gear(3) Bar(4) Lock bolt

1

2

4

3

Legend

(1) O-Ring

(2) High Pressure Oil Pump Assembly

(3) Nut

(4) O-Ring

040RW007

41

2

3

014RW177


12. Remove high pressure oil pump

13. Remove high pressure oil pump assembly

Legend(1) O-ring(2) High pressure oil pump(3) Nut(4) O-ring

1

2

4

3

040RW007


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 timinggear case.

Tighten nut to specified torque.

Torque: 20 N·m (2.0 kg·m/14.5 lb ft)

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

2. Tighten high pressure oil pump assembly brackettogether with two way valve bracket.


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

3. Install the pump gear to align timing mark with idlegear A.

Tighten high pressure pump gear fixing bolt to thespecified torque.

Apply engine oil to thread and seat of bolt.

Torque: 75 N·m (7.6 kg·m/55 lb ft)

Legend(1) O-ring(2) Pump Gear(3) Bolt(4) Timing Mark

1

2

4

3

040RW007

2

34

1

040RW006

4GEAR:O/PUMP

IDLE GEAR A

1

2

3

040RW005


4. Remove lock bolt of idle gear A.

5. Install timing gear case cover.

Refer to “Timing gear” in this manual.

6. Install front plate.


7. Install timing pulley of high pressure oil pump.


8. Install timing belt and tighten timing belt tensionerassembly.

Refer to “Cylinder head” in this manual.

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.


10. Connect CMP sensor cable.

11. Install timing belt cover.


12. Fill with about 300 cc of engine oil from the highpressure oil pipe installation port of the oil rail usingan oil filler.

If assembled without filling the oil rail with oil, thetime for engine starting will be longer.

13. Immediately install high pressure oil pipe andtighten 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.


14. Install the crankshaft damper pulley with specifiedtorque.

Torque: 220 N·m (22 kg·m/159 lb ft)

15. Install the intercooler assembly.

Refer to “Intercooler” in this manual.

16. Install air cleaner cover and air duct.

1

2

3

8

6

7

45

F06RW055


HIGH PRESSURE OIL PIPE INSTALLATION

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

2. Install pipe A to two way valve, tighten pipe Atemporarily 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 Eand 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 nutC, D, F, and E to the specified torque.


7. Tighten lower bracket to the specified torque.


NOTE: Wash inside pipe, inside union nut and O-ringseal surface to remove engine oil and foreign materials.

6

5

7

9

8

11

4

1

2

3

10

Legend

(1) Union Nut F

(2) Pipe B

(3) Union Nut E

(4) Upper Bracket

(5) Two Way Valve

(6) Union Nut D

(7) Pipe A

(8) Union Nut C

(9) Lower Bracket

(10) To Oil Rail

(11) To High Pressure Oil Pump

052R200001


FUEL TANK

REMOVAL


2. Remove fuel filler cap.

3. Drain fuel.

After drain the fuel tighten the drain plug withspecified torque.


4. Remove fuel filler hose and let air pull off hose.

5. Remove breather hose.

6. Remove fuel feed hose and fuel return hose.

7. Disconnect harness connector from fuel gauge unit.

8. Remove under cover.

9. Remove fuel tank assembly.

INSTALLATION

1. Fuel tank assembly.

1) Place a flange on right side of tank on thebracket.

2) Install a flange to left side of the bracket from thebottom, and tighten bolts to the specified torque.


2. Install fuel hose and fuel return hose.

3. Install the breather hose.

4. Reconnect harness connector to fuel gauge unit.

5. Install under cover.

6. Install fuel filler hose and let air pull off hose.

7. Fill fuel tank with fuel and tighten filler cap.

8. Reconnect battery ground cable.

1

2

4

8

6

7

8

Europe, Nicaragua, Argentina, Philippin

6

5

3

Legend

(1) Fuel Tank Assembly

(2) Gauge Unit

(3) Bolt

(4) Under Cover

(5) Bolt

(6) Fuel Filler Hose

(7) Fuel Filler Cap

(8) Breather Hose

140R200032


FUEL GAUGE UNIT

1

2

3

140R200033

REMOVAL


2. Loosen fuel filler cap.

3. Drain fuel.

After drain the fuel tighten the drain plug withspecified torque.


4. Disconnect harness connector from fuel gauge unit.

5. Fuel Gauge Unit

1) Remove the fixing screws, then the fuel gaugeunit.

INSTALLATION

1. Fuel Gauge Unit

2. Connect the harness connector to the fuel gageunit.

3. Fill the tank with fuel and tighten fuel filler cap.

4. Connect battery ground cable.

FUEL FILLER CAPThe fuel filler cap contains a vacuum valve. If anegative pressure develops in the fuel tank, theexternal valve of the fuel filler cap opens to allow thefresh air to flow into the fuel tank through the vacuumvalve.

INSPECTION

Check the seal ring in the filler cap for presence of anyabnormality and for seal condition.

Replace the filler cap, if abnormal.

Legend(1) Vacuum Valve(2) Pressure Valve(3) Seal Ring

Legend

(1) Fuel Tank Assembly

(2) Fuel Gauge Unit

(3) Drain Plug

1

3

2

060R200247

jackaroo ubs-73 workshop manual -...

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