ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Injectors

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REMOVAL & INSTALLATION



  1. Remove the fuel pressure line(s) and return line(s) from the fuel injector(s).
  2.  
  3. Remove the fuel injector(s) from the engine.
  4.  
  5. Remove the O-rings from the fuel injector(s).
  6.  

To install:
  1. Using new O-rings, lubricate them in diesel fuel and install them onto the fuel injector(s).
  2.  
  3. Install the fuel injector(s) into the engine.
  4.  
  5. Using new O-rings, install the fuel pressure line(s) and return line(s) to the fuel injector(s).
  6.  

TESTING



See Figures 1 and 2


CAUTION
When using the injector tester, test fluid will spray out of the injector nozzle at high pressure, which can easily puncture the skin or eyes. Since a defective injector may spray in any direction, make sure that hands and eyes are away from the injector outlet and that protective clothing and safety glasses are used.



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Fig. Fig. 1: A special tester is available to check opening pressure and spray patterns



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Fig. Fig. 2: Injector spray patterns. First pattern is good, the rest are bad

  1. Remove the injector and install injector tester J-28829 or equivalent. Measure the injector pressure. Pressure should be:

    C223 engine-1493 psi (105 kg/cm)
     
    C223-T engine-1920 psi (135 kg/cm)
     

  2.  
  3. Using injector tester J-28829 or equivalent, maintain a pressure of 284 psi (20 kg/cm). If there is no leakage, the injector is satisfactory.
  4.  
  5. Observe the spray pattern coming from the outlet. It should be a fine uniform spray. If not, clean or replace the injector.
  6.  

DISASSEMBLY & ASSEMBLY



See Figures 3 and 4



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Fig. Fig. 3: Exploded view of the fuel injector



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Fig. Fig. 4: Adjusting the fuel injector

  1. Remove the injector from the vehicle.
  2.  
  3. Place the injector in a vise, clamping the hexagonal portion in the vise. Loosen the retaining nut and remove it.
  4.  
  5. Remove the eye bolt, gasket, cap nut and gasket.
  6.  
  7. Remove the adjusting screw, nozzle spring and pushrod.
  8.  
  9. Remove the inlet connector, gasket and retaining nut.
  10.  
  11. Remove the setting screw and nozzle from the holding body.
  12.  

To install:
  1. Install the nozzle and setting screw.
  2.  
  3. Install the inlet connector, gasket and retaining nut.
  4.  
  5. Install the adjusting screw, nozzle spring and pushrod.
  6.  
  7. Using the injector holder and injector tester, adjust the opening pressure by setting the pressure adjusting screw until the desired pressure is obtained.
  8.  
  9. Install the cap nut and tighten to 22-29 inch lbs. (3-4 Nm).
  10.  
  11. Assemble the injector and tighten the retaining nut to 65 ft. lbs. (88 Nm).
  12.  

CLEANING



See Figure 5



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Fig. Fig. 5: Cleaning the fuel injector

Remove the carbon from the outside of the nozzle body with a soft brush. Clean the internal portion of the body with rod J-28826-2 or equivalent. Clean the nozzle seat of the body with cleaning tool J-28826 or equivalent. Clean the injection hole of the body with rod J-28826-4 or equivalent.

 
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