Isuzu Cars and Trucks 1981-1991

Diesel Injection Pump

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REMOVAL AND INSTALLATION
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover.
  4.  
  5. Remove the fuel lines and disconnect the electrical connectors from the fuel injector.
  6.  
  7. Using a pry bar, remove the tension spring from the timing belt tensioner.
  8.  


NOTE
When removing the tension spring, avoid using excessive force for the spring may become distorted.

  1. Remove the tensioner pulley bolt and the pulley.
  2.  
  3. Remove the timing belt and discard it.
  4.  
  5. Using a 6mm, 1.25 pitch bolt, install the threaded portion into the threaded hole in the timing pulley housing through the hole in the pulley to prevent the pulley from turning.
  6.  
  7. Remove the injection pump pulley-to-shaft bolts.
  8.  
  9. Using a wheel puller, connect it to the injection pump pulley and press it from the shaft.
  10.  
  11. Remove the injection pump bracket-to-timing pulley housing bolts, the rear injection pump-to-bracket bolts and the injection pump.
  12.  



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Fig. Diesel injection pump 4FB1 diesel engine



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Fig. Diesel injection pump C223 and C223-T diesel engines

To install:

  1. Install the injection pump. Tighten the injection pump-to-timing pulley housing bolts and leave the rear pump-to-bracket bolts semi-tight.
  2.  
  3. Install the injection pump pulley by aligning it with the key groove and torque the bolt to 42 and 1952 ft. lbs. (57 and 1970 Nm).
  4.  
  5. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.
  6.  
  7. Align the timing marks on the injection pump pulley with the camshaft pulley; the marks must be facing each other.
  8.  
  9. Using a new timing belt, install it in the following sequence: crankshaft pulley, camshaft pulley and the injection pump pulley; the slack must be between the injection pump and camshaft pulleys.
  10.  
  11. Install the tension center and the tension pulley so the end of the tension center is fitted against both pins on the timing pulley housing.
  12.  
  13. Hand tighten the nut so the tension pulley can be rotated freely.
  14.  
  15. Install the tension spring and semi-tighten the pulley nut to 22 and 1936 ft. lbs. (29 and 1948 Nm).
  16.  
  17. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90and#x00B0; beyond TDC to settle the injection pump.
  18.  
  19. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79 and 1994 ft. lbs. (108 and 19130 Nm).
  20.  
  21. Install the injection pump pulley flange; the hole in the outer circumference of the flange should be aligned with the triangular timing mark on the injection pump pulley.
  22.  
  23. Rotate the crankshaft 2 full turns clockwise to bring the No. 1 piston to TDC of the compression stroke. Make sure the triangular timing mark on the timing pulley is aligned with the hole in the flange, then, measure the timing belt tension; it should be 33 and 1955 lbs.
  24.  
  25. Install the timing belt cover.
  26.  
  27. Connect the negative battery cable.
  28.  

Idle Speed

Refer to the "Idle Speed" procedures for diesel engines in .

INJECTION TIMING
  1. Check to see if the notched line on the injection pump and mounting plate are aligned.
  2.  
  3. Bring the No. 1 piston to top dead center on the compression stroke by turning the crankshaft. The correct notch must be used for alignment as the damper pulley is provided with a total of seven notches.
  4.  
  5. Remove the front upper timing belt cover, check the timing belt for proper tension and alignment of the timing marks.
  6.  
  7. Remove the cam cover and rear plug, then check that the fixing plate fits smoothly into the slit at the rear end of the camshaft, then remove the fixing plate J29761.
  8.  
  9. Disconnect the injection pipe from the injection pump and remove the distributor head screw and gasket, then install a static timing gauge. Set the lift about 1mm from the plunger.
  10.  



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Fig. Diesel injection pump timing mark all diesel engines



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Fig. Diesel crankshaft timing indicator 4FB1 engine



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Fig. Timing marks 4FB1 engine



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Fig. Camshaft fixing plate 4FB1 engine



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Fig. Timing indicator C223 diesel engine



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Fig. Timing to specifications refer to specifications chart, C223 engine



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Fig. Injection pump timing all diesel engines

  1. Bring the piston in No. 1 cyl. to a point 45 and 1960and#x00B0; before top dead center by turning the crankshaft, then calibrate the dial indicator to zero.
  2.  
  3. The damper is provided with notched lines as illustrated. The four lines at one side are for static timing and should be used for service purposes. The three lines are for dynamic timing and used only at the factory.
  4.  
  5. Turn the crankshaft until the line 12and#x00B0; on the damper is brought into alignment with the pointer, then take a reading of the dial indicator. The standard reading is 0.5mm.
  6.  
  7. If the reading on the dial indicator deviates from the specified range, hold the crankshaft to the "Injection Pump Setting" in the diesel tune-up specifications chart. Loosen the two nuts on the injection pump flange.
  8.  
  9. Move the pump to a point where the dial indicator gives a reading of 0.5mm. Tighten the flange nuts.
  10.  



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Fig. Diesel fuel system diagnosis Chart 1



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Fig. Diesel fuel system diagnosis Chart 2



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Fig. Diesel fuel system diagnosis Chart 3



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Fig. Diesel fuel system diagnosis Chart 4



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Fig. Diesel fuel system diagnosis Chart 5



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Fig. Diesel fuel system diagnosis Chart 6



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Fig. Diesel fuel system diagnosis Chart 7



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Fig. Diesel fuel system diagnosis Chart 8



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Fig. Diesel fuel system diagnosis Chart 9



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Fig. Diesel fuel system diagnosis Chart 10



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Fig. Diesel fuel system diagnosis Chart 11



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Fig. Diesel fuel system diagnosis Chart 12



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Fig. Diesel fuel system diagnosis Chart 13

 
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