Fuel inspection (RZ4E-TC)

1. Fuel safety information

Caution
Including the inside of the injector, the holes and gaps that are the fuel paths for the fuel system have
an extremely precise finish.
Because there is a possibility of damage if foreign material enters, cap or cover after removing parts,
etc., to thoroughly prevent foreign material from entering.
Add a cleaning fluid to the steam cleaner and thoroughly clean the sensor, common rail (fuel rail), and
supply pump areas.
Completely remove moisture with an air blower.
Verify that all foreign material has been completely removed before starting the procedure.
After replacing the various sensors, use the scan tool to verify that the trouble code is cleared and

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that the sensors are operating normally.
Because fuel leakage may lead to fire, wipe off the leaked fuel after completing the work and after the
inspection, and be sure to check for fuel leaks after starting the engine.

2. Fuel vehicle inspection

1) Start the engine.

2) Inspect the fuel system for loose connections.

Note
Inspect for fuel leakage.
Fuel air bleed (RZ4E-TC)

1. Fuel air bleed

1) Open the engine hood.

2) Press the priming pump until it becomes hard.

Caution
Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.

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Legend

1. Priming pump
2. Fuel filter with sedimenter
Fuel drain water (RZ4E-TC)

1. Fuel drain water

If the warning light illuminates, refer to the following procedure to drain the water.

Caution
If the warning light frequently illuminates, drain the fuel in the fuel tank, then perform the work.
When draining the fuel from the fuel tank, make sure to stop the engine.
Make sure that no flammable objects are around the container when draining the fuel.

1) Prepare pan.

2) Install the clear hose to the drain plug on the fuel filter.

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Note
Place the container at the end of the hose attached to the drain plug.

3) Loosen the drain plug to drain moisture and deposits.

4) Push the priming pump several times to check for fuel leakage.

5) Tighten the drain plug.

Tightening torque: 1.0 N・m { 0.10 kgf・m / 8.9 lb・in }

6) Turn ON the ignition switch for 15 seconds.

7) Confirm that the warning light turns OFF.

Common rail (fuel rail) removal (RZ4E-TC)

1. Component views

Common rail (fuel rail)

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Part name

1. Common rail (fuel rail)

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Preliminary and post procedures

 1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

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4. Engine oil drain

1) Remove the drain plug from the oil pan, and drain the engine oil to a pan.

2) Install the drain plug to the oil pan.

Caution
Do not reuse the gasket.
Wipe off any oil attached to the drain plug hole.
Do not forget to tighten the drain plug.

Tightening torque: 83 N・m { 8.5 kgf・m / 61 lb・ft }

5. Coolant drain

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.
3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

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Legend

1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

6. Engine cover removal

1) Remove the engine cover from the engine.

 Legend

1. Engine cover

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7. Oil level gauge guide tube removal

1) Remove the oil level gauge from the oil level gauge guide tube.

2) Remove the oil level gauge guide tube from the crankcase.

8. Intake throttle valve removal

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Intake throttle valve removal".

9. Water pipe removal

1. Except Euro4 specifications (Specifications for models with heaters)

1) Disconnect the vacuum hose from the vacuum pipe.

2) Remove the vacuum pipe from the air duct bracket.

Legend

1. Vacuum pipe

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2. Vacuum hose
3. Bracket

3) Disconnect the heater hose from the water pipe.

4) Remove the water pipe from the air duct bracket.

5) Remove the pipe clip from the water pipe.

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6) Remove the water pipe from the inlet cover.
2. Except Euro4 specifications (Specifications for models without heaters)

1) Disconnect the vacuum hose from the vacuum pipe.

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2) Remove the vacuum pipe from the air duct bracket.

Legend

1. Vacuum pipe
2. Vacuum hose
3. Bracket

3) Remove the water hose from the water pipe.

4) Remove the water pipe from the air duct bracket.

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5) Remove the pipe clip from the water pipe.
6) Remove the water pipe from the inlet cover.

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10. EGR cooler water hose disconnect

1. Euro4 specifications

1) Disconnect the EGR cooler water feed hose from the EGR cooler.
Legend

1. EGR cooler water return hose

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2. EGR cooler water feed hose

2) Disconnect the heater hoses from the EGR cooler.

3) Disconnect the heater hose from the EGR cooler water return pipe.

4) Disconnect the EGR cooler water hose from EGR cooler water pipe A.

5) Remove EGR cooler water pipe A from the inlet cover.

 Legend

1. EGR cooler water pipe A

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2. EGR cooler water hose
3. EGR cooler water pipe B

11. Injection pipe removal

1) Clean the injector and injector bracket using an air blower.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution
Do not reuse the injection pipe.

12. Fuel feed pipe removal

1) Remove the clip from the fuel feed pipe.

2) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).
 Caution
Do not reuse the fuel feed pipe.
Cover the exposed section to prevent the intrusion of foreign material.

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Legend

1. Fuel feed pipe

13. Fuel leak-off pipe removal

1) Disconnect the fuel leak-off hose from the fuel leak-off pipe.

2) Remove the fuel leak-off pipe from the common rail (fuel rail) and flywheel housing.

Caution
Cover the exposed section to prevent the intrusion of foreign material.

Legend

1. Fuel leak-off pipe

14. Common rail (fuel rail) removal

1) Remove the bracket from the cylinder head.

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2) Disconnect the connector from the FRP sensor.

3) Remove the common rail (fuel rail) from the cylinder head.

Caution
Do not hold the FRP sensor.
Take care not to damage the connector section of the FRP sensor.
Common rail (fuel rail) installation (RZ4E-TC)

1. Component views

Common rail (fuel rail)

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Part name

1. Common rail (fuel rail)

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Common rail (fuel rail) installation

1) Install the common rail (fuel rail) to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Caution
Do not hold the FRP sensor.
Take care not to damage the connector section of the FRP sensor.

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2) Install the connector to the FRP sensor.

3) Install the bracket to the cylinder head.

Note
Install so that the detent makes contact with the common rail (fuel rail).

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Legend

1. Detent
3. Fuel leak-off pipe installation

1) Install the fuel leak-off pipe to the common rail (fuel rail) and flywheel housing.

Tightening torque: 20.2 N・m { 2.1 kgf・m / 15 lb・ft } Common rail (fuel rail) side

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Flywheel housing side

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Legend

1. Fuel leak-off pipe

2) Connect the fuel leak-off hose to the fuel leak-off pipe.

4. Fuel feed pipe installation

1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

Legend
 1. Fuel feed pipe

2) Install the clip to the fuel feed pipe.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5. Injection pipe installation

1) Temporarily tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the
diagram.

Caution
Do not reuse the injection pipe.

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2) Final tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the diagram.

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

6. EGR cooler water hose connect

1. Euro4 specifications
1) Install EGR cooler water pipe A to the inlet cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Connect the EGR cooler water hose to EGR cooler water pipe A.

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Legend

1. EGR cooler water pipe A

2. EGR cooler water hose
3. EGR cooler water pipe B

3) Connect the heater hose to EGR cooler water pipe A.

4) Connect the heater hoses to the EGR cooler.

5) Connect the EGR cooler water feed hose to the EGR cooler.
 Legend

1. Heater hose

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2. EGR cooler water feed hose

7. Water pipe installation

1. Except Euro4 specifications (Specifications for models with heaters)

1) Install the water pipe to the inlet cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Remove the pipe clip from the water pipe.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Install the water pipe to the air duct bracket.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

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4) Connect the heater hose to the water pipe.
5) Install the vacuum pipe to the air duct bracket.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

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6) Connect the vacuum hose to the vacuum pipe.

Legend

1. Vacuum pipe
2. Vacuum hose
3. Bracket

2. Except Euro4 specifications (Specifications for models without heaters)

1) Install the water pipe to the inlet cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Remove the pipe clip from the water pipe.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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3) Install the water pipe to the air duct bracket.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

4) Install the water hose to the water pipe.

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5) Install the vacuum pipe to the air duct bracket.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

6) Connect the vacuum hose to the vacuum pipe.

 Legend

1. Vacuum pipe

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2. Vacuum hose
3. Bracket

8. Intake throttle valve installation

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Intake throttle valve installation".

9. Oil level gauge guide tube installation

1) Apply engine oil to the O-ring.

2) Install the oil level gauge guide tube to the crankcase.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Install the oil level gauge to the oil level gauge guide tube.

10. Engine cover installation

1) Install the engine cover to the engine.

 Legend

1. Engine cover

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11. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

12. Engine oil filling

1) Replenish the engine with the engine oil.

2) Check the tightening of the oil pan drain plug.

Tightening torque: 83 N・m { 8.5 kgf・m / 61 lb・ft }

13. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

14. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
Caution
Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

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Legend

1. Radiator reserve tank

2. MAX line
3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.

Caution
Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

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14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
Filler neck removal (RZ4E-TC)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.

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If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3) Raise the vehicle.

2. Fuel filler cap removal

1) Loosen the fuel filler cap gradually.

Caution
The fuel may burst out due to the pressure change in the fuel tank.

2) Remove the fuel filler cap from the filler neck.

Caution
Seal the filler neck to prevent foreign material from entering.

3. Rear mudguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors rear mudguard removal".

4. Filler neck removal

1) Place marks on the filler neck clamp, each fixing section, and band clip.

2) Remove the filler neck from the rear body and fuel filler hose.

Caution
Seal the hose and pipe to prevent foreign material from entering.

3) Disconnect the breather hose from the filler neck.

Caution
Seal the hose and pipe to prevent foreign material from entering.

4) Disconnect the evaporator hose from the filler neck.

Caution
Seal the hose and pipe to prevent foreign material from entering.

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Legend

1. Fuel filler hose

2. Evaporator hose
3. Breather hose
Filler neck installation (RZ4E-TC)

1. Filler neck installation

1) Connect the evaporator hose to the filler neck.

Caution
Install to the original position by aligning the marks applied before removing.

2) Connect the breather hose to the filler neck.

Caution
Install to the original position by aligning the marks applied before removing.

3) Install the filler neck to the rear body and fuel filler hose.

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Caution
Install to the original position by aligning the marks applied before removing.

Tightening torque: 6.0 N・m { 0.6 kgf・m / 53 lb・in } Screw

Tightening torque: 3.5 N・m { 0.36 kgf・m / 31.0 lb・in } Clamp

Legend

1. Fuel filler hose

2. Evaporator hose
3. Breather hose

2. Rear mudguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors rear mudguard installation".
3. Fuel filler cap installation

1) Install the fuel filler cap to the filler neck.

Caution
Tighten it until it clicks at least 3 times.

4. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

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Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

5. Fuel vehicle inspection

1) Start the engine.

2) Inspect the fuel system for loose connections.

Note
Inspect for fuel leakage.
FRP regulator removal (RZ4E-TC)

1. Component views

FRP regulator

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Part name

1. Bolt
2. FRP regulator
3. O-ring
4. Fuel supply pump

Tightening torque

1: 9.0 N・m { 0.9 kgf・m / 80 lb・in }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

 Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3. Engine oil drain

1) Remove the drain plug from the oil pan, and drain the engine oil to a pan.

2) Install the drain plug to the oil pan.

Caution
Do not reuse the gasket.
Wipe off any oil attached to the drain plug hole.

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Do not forget to tighten the drain plug.

Tightening torque: 83 N・m { 8.5 kgf・m / 61 lb・ft }

4. Oil level gauge guide tube removal

1) Remove the oil level gauge from the oil level gauge guide tube.

2) Remove the oil level gauge guide tube from the crankcase.

5. FRP regulator removal

1) Disconnect the connector from the FRP regulator.

Caution
Do not damage the connector by applying excessive force.
Legend

1. FRP regulator
2. Fuel temperature sensor

2) Remove the FRP regulator from the fuel supply pump.

3) Remove the O-ring from the fuel supply pump.

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Legend

1. O-ring
FRP regulator installation (RZ4E-TC)

1. Component views

FRP regulator

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Part name

1. Bolt
2. FRP regulator
3. O-ring
4. Fuel supply pump

Tightening torque

1: 9.0 N・m { 0.9 kgf・m / 80 lb・in }

2. FRP regulator installation

1) Install the O-ring to the fuel supply pump.

 Legend

1. O-ring

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2) Temporarily tighten the FRP regulator by hand until it attaches securely to the fuel supply pump.

Caution
Do not allow the O-ring to get caught.

3) Final tighten the FRP regulator to the fuel supply pump.

Tightening torque: 9.0 N・m { 0.9 kgf・m / 80 lb・in }

4) Connect the connector to the FRP regulator.

3. Oil level gauge guide tube installation

1) Apply engine oil to the O-ring.

2) Install the oil level gauge guide tube to the crankcase.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Install the oil level gauge to the oil level gauge guide tube.

4. Engine oil filling

1) Replenish the engine with the engine oil.

2) Check the tightening of the oil pan drain plug.

Tightening torque: 83 N・m { 8.5 kgf・m / 61 lb・ft }

5. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

6. ECM setting

Note
If repairing or replacing the fuel supply pump, perform Fuel Supply Pump Relearning.

1. Fuel Supply Pump Relearning

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

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3) Select the scan tool item.

Diagnostics
Engine
RZ4E
Actuator Test
Fuel Supply Pump Learn Resetting

4) Reset the Fuel Supply Pump Learning by following the on-screen instructions.

5) Turn OFF the ignition switch for 30 seconds.

6) Start and idle the engine until the engine coolant temperature reaches 65°C {149°F} or more.

7) Observe the Fuel Supply Pump Learning Status parameter on the scan tool.

8) The procedure is complete when the parameter changes from Not Learned to Learned.
Fuel filler cap removal (RZ4E-TC)

1. Fuel filler cap removal

1) Loosen the fuel filler cap gradually.

Caution
The fuel may burst out due to the pressure change in the fuel tank.

2) Remove the fuel filler cap from the filler neck.

Caution
Seal the filler neck to prevent foreign material from entering.

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Fuel filler cap inspection (RZ4E-TC)

1. Fuel filler cap inspection

1) Inspect the seal ring of the fuel filler cap.

Caution
Because replacing may cause an engine performance decrease, make sure to use the same type.

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Legend

1. Seal ring
Fuel filler cap installation (RZ4E-TC)

1. Fuel filler cap installation

1) Install the fuel filler cap to the filler neck.

Caution
Tighten it until it clicks at least 3 times.

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Fuel filter element removal (RZ4E-TC)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.

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If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

2. Fuel filter element removal

1) Remove the element case and O-ring from the fuel filter body.

2) Remove the fuel filter element from the element case.

Caution
Do not reuse the O-ring or gasket.
Use an ISUZU genuine fuel filter for element replacement.

Legend
1. Fuel filter body
2. Fuel filter element
3. O-ring
4. Element case

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Fuel filter element installation (RZ4E-TC)

1. Fuel filter element installation

1) Install the fuel filter element to the element case.

2) Install the element case and O-ring to the fuel filter body.

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Legend

1. Fuel filter body

2. Fuel filter element
3. O-ring
4. Element case

2. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

3. Fuel air bleed

1) Press the priming pump until it becomes hard.

Caution
Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.

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Legend

1. Priming pump
2. Fuel filter with sedimenter
Fuel filter removal (RZ4E-TC)

1. Component views

Fuel filter

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Part name

1. Pressure switch
2. Priming pump
3. Fuel feed hose (Fuel tank side)
4. Fuel filter
5. Fuel return hose
6. Fuel feed hose (Supply pump side)

2. Preliminary and post procedures

 1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3. Fuel filter removal

1) Disconnect the connector from the fuel sedimenter switch.

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2) Disconnect the connector from the pressure switch.

3) Remove the fuel filter from the fuel filter bracket.

4) Disconnect the fuel feed hose from the fuel filter.

Caution
Insert a plug so that fuel does not spill.
Fuel filter inspection (RZ4E-TC)

1. Fuel filter inspection

1) Inspect for continuity between the pressure switch terminals using a DMM.

Note
If there is continuity, replace the fuel filter.

2) Connect the vacuum pump to the engine side feed pipe of the fuel filter.

3) Seal the feed pipe on the fuel tank side using caps, cloth tape, etc.

Caution
Make sure to prevent fuel from entering the vacuum pump.

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4) Apply a vacuum using a vacuum pump, and inspect for continuity when pressurizing to the standard value.

Standard: -38 to -42 kPa { -0.39 to -0.43 kgf/cm2 / 285 to 315 mmHg }

Note
If there is no continuity, replace the fuel filter.
Fuel filter installation (RZ4E-TC)

1. Component views

Fuel filter

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Part name

1. Pressure switch
2. Priming pump
3. Fuel feed hose (Fuel tank side)
4. Fuel filter
5. Fuel return hose
6. Fuel feed hose (Supply pump side)

2. Fuel filter installation

 1) Connect the fuel feed hose to the fuel filter.

2) Install the fuel filter to the fuel filter bracket.

3) Connect the connector to the pressure switch.

4) Connect the connector to the fuel sedimenter switch.

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3. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

4. Fuel air bleed

1) Press the priming pump until it becomes hard.

Caution
Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.
Legend

1. Priming pump

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2. Fuel filter with sedimenter
Fuel supply pump removal (RZ4E-TC)

1. Component views

Fuel supply pump

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Part name

1. Bolt
2. Fuel supply pump
3. O-ring
4. Nut
5. Bolt
6. Supply pump bracket
7. O-ring
8. Supply pump gear
9. Supply pump gear nut

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

9: 63.7 N・m { 6.5 kgf・m / 47 lb・ft }

2. Starter motor removal

Refer to "1.Engine 1J.Electrical(RZ4E-TC) starter motor removal".

3. Inlet cover removal

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) inlet cover removal".

4. Fuel feed pipe removal

1) Remove the clip from the fuel feed pipe.

2) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).

Caution
Do not reuse the fuel feed pipe.
Cover the exposed section to prevent the intrusion of foreign material.

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Legend

1. Fuel feed pipe

5. Fuel supply pump removal

1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top
dead center.
Legend

1. Top dead center alignment mark on the water inlet pipe side

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2. Top dead center alignment mark on the crank pulley side

2) Disconnect the connector from the fuel temperature sensor.

3) Disconnect the connector from the FRP regulator.

Legend

1. FRP regulator connector

2. Fuel temperature sensor connector

4) Disconnect the fuel suction hose from the fuel supply pump.

5) Disconnect the fuel leak-off hose from the fuel supply pump.
Legend

1. Fuel leak-off hose

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2. Fuel suction hose

6) Remove the fuel supply pump and adapter from the cylinder block.

Caution
Do not hold the high pressure pipe.

Legend

1. Fuel supply pump

2. Adapter

7) Use bolts to secure the supply pump gear to the adapter.

Note
Use M8 x 1.25 bolts with a length of 35 mm {1.38 in} or more.

Caution
Secure the bolts and adapter in 3 or more locations.
Legend

1. Supply pump gear securing holes

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2. Lock bolt hole
3. Adapter

8) Remove the supply pump gear nut from the fuel supply pump.

9) Remove the supply pump gear from the fuel supply pump using a gear puller.

10) Remove the adapter from the fuel supply pump.

Legend

1. Fuel supply pump

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2. Adapter

11) Remove the O-ring from the adapter.

12) Remove the O-ring from the fuel supply pump.

Legend

1. O-ring
2. Adapter
3. O-ring
4. Fuel supply pump
Fuel supply pump installation (RZ4E-TC)

1. Component views

Fuel supply pump

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Part name

1. Bolt
2. Fuel supply pump
3. O-ring
4. Nut
5. Bolt
6. Supply pump bracket
7. O-ring
8. Supply pump gear
9. Supply pump gear nut

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

9: 63.7 N・m { 6.5 kgf・m / 47 lb・ft }

2. Fuel supply pump installation

1) Apply engine oil to the O-ring.

2) Install the O-ring to the fuel supply pump.

3) Install the O-ring to the adapter.

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Legend

1. O-ring
2. Adapter
3. O-ring
4. Fuel supply pump

4) Install the fuel supply pump to the adapter.

Caution
Do not pinch the O-ring.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Legend

1. Fuel supply pump

2. Adapter

5) Temporarily tighten the supply pump gear to the fuel supply pump.

6) Use bolts to secure the supply pump gear to the adapter.

Note
Use M8 x 1.25 bolts with a length of 35 mm {1.38 in} or more.

Caution
Secure the bolts and adapter in 3 or more locations.

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Legend

1. Supply pump gear securing holes

2. Lock bolt hole
3. Adapter

7) Final tighten the supply pump gear to the fuel supply pump.

Tightening torque: 63.7 N・m { 6.5 kgf・m / 47 lb・ft }

8) Remove the bolts from the adapter.

9) Install the M6 lock bolt to the adapter.

Legend

1. Supply pump gear securing holes

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2. Lock bolt hole
3. Adapter

10) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top
dead center.

Legend

1. Top dead center alignment mark on the water inlet pipe side
2. Top dead center alignment mark on the crank pulley side

11) Install the fuel supply pump and adapter to the cylinder block.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Legend

1. Fuel supply pump

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2. Adapter

12) Remove the plug from the flywheel housing.

Legend

1. Plug
2. Flywheel housing
3. Fuel supply pump

13) Remove the lock bolt from adapter.

14) Install the plug to the flywheel housing.

Caution
Do not reuse the gasket.

Tightening torque: 63 N・m { 6.4 kgf・m / 46 lb・ft }

 15) Connect the fuel leak-off hose to the fuel supply pump.

16) Connect the fuel suction hose to the fuel supply pump.

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Legend

1. Fuel leak-off hose

2. Fuel suction hose

17) Connect the connector to the FRP regulator.

18) Connect the connector to the fuel temperature sensor.

Legend

1. FRP regulator connector

2. Fuel temperature sensor connector

3. Fuel feed pipe installation

1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).
 Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

Legend

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1. Fuel feed pipe

2) Install the clip to the fuel feed pipe.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

4. Inlet cover installation

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) inlet cover installation".

5. Starter motor installation

Refer to "1.Engine 1J.Electrical(RZ4E-TC) starter motor installation".

6. Fuel air bleed

1) Open the engine hood.

2) Press the priming pump until it becomes hard.

Caution
Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.
Legend

1. Priming pump

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2. Fuel filter with sedimenter

7. ECM setting

Note
If repairing or replacing the fuel supply pump, perform Fuel Supply Pump Relearning.

1. Fuel Supply Pump Relearning

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

Diagnostics
Engine
RZ4E
Actuator Test
Fuel Supply Pump Learn Resetting

4) Reset the Fuel Supply Pump Learning by following the on-screen instructions.

5) Turn OFF the ignition switch for 30 seconds.

6) Start and idle the engine until the engine coolant temperature reaches 65°C {149°F} or more.

7) Observe the Fuel Supply Pump Learning Status parameter on the scan tool.

8) The procedure is complete when the parameter changes from Not Learned to Learned.
Fuel tank removal (RZ4E-TC)

1. Component views

Fuel tank

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Part name

1. Fuel feed tube

2. Fuel tank
3. Fuel filler hose
4. Breather hose
5. Evaporator hose
6. Bolt
7. Fuel tank band
8. Fuel return tube
9. Fuel tank protector
 Tightening torque

6: 68 N・m { 6.9 kgf・m / 50 lb・ft }

2. Fuel filler cap removal

1) Loosen the fuel filler cap gradually.

Caution
The fuel may burst out due to the pressure change in the fuel tank.

2) Remove the fuel filler cap from the filler neck.

Caution
Seal the filler neck to prevent foreign material from entering.

3. Fuel tube disconnect

1) Disconnect the fuel feed hose from the fuel feed tube.

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Caution
Plug to prevent fuel from coming out, then face it upward and tie it to the frame side.

2) Disconnect the fuel return hose from the fuel return tube.

Caution
Plug to prevent fuel from coming out, then face it upward and tie it to the frame side.

Legend

1. Fuel feed tube

2. Fuel return tube

4. Fuel tank removal

1) Disconnect the fuel filler hose from the filler neck.

Caution
 Seal the hose and pipe to prevent foreign material from entering.

2) Disconnect the breather hose from the filler neck.

Caution
Seal the hose and pipe to prevent foreign material from entering.

3) Disconnect the evaporator hose from the filler neck.

Caution
Seal the hose and pipe to prevent foreign material from entering.

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Legend

1. Fuel filler hose

2. Evaporator hose
3. Breather hose

4) Support the lower section of the fuel tank using the lifter.

5) Remove the fuel tank band from the frame.

6) Disconnect the connector from the fuel tank unit.

7) Remove the fuel tank from vehicle.

8) Lower the lifter and remove the fuel tank from the vehicle.

Caution
Do not let the fuel hose and fuel tube interfere with other components.

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Fuel tank installation (RZ4E-TC)

1. Component views

Fuel tank

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Part name

1. Fuel feed tube

2. Fuel tank
3. Fuel filler hose
4. Breather hose
5. Evaporator hose
6. Bolt
7. Fuel tank band
8. Fuel return tube
9. Fuel tank protector
 Tightening torque

6: 68 N・m { 6.9 kgf・m / 50 lb・ft }

2. Fuel tank installation

1) Support the fuel tank using the lifter.

2) Install the fuel tank to the vehicle by raising the lifter.

Caution
Do not let the fuel hose and tube interfere with other components.

3) Connect the connector to the fuel tank unit.

Caution
Securely connect the connector to the stopper.

4) Install the fuel tank band to the frame.

Tightening torque: 68 N・m { 6.9 kgf・m / 50 lb・ft }

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Caution
Securely install the tank band anchor to the guide hole of the frame.

5) Connect the evaporator hose to the filler neck.

6) Connect the breather hose to the filler neck.

7) Connect the fuel filler hose to the filler neck.

Tightening torque: 3.5 N・m { 0.36 kgf・m / 31.0 lb・in } Clamp

 Legend

1. Fuel filler hose

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2. Evaporator hose
3. Breather hose

8) Remove the lifter from the fuel tank.

3. Fuel tube connect

1) Connect the fuel return hose to the fuel return tube.

2) Connect the fuel feed hose to the fuel feed tube.

Legend

1. Fuel return tube

2. Fuel feed tube

4. Fuel filler cap installation

 1) Install the fuel filler cap to the filler neck.

Caution
Tighten it until it clicks at least 3 times.

5. Fuel air bleed

1) Press the priming pump until it becomes hard.

Caution
Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.

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Legend

1. Priming pump
2. Fuel filter with sedimenter

6. Fuel vehicle inspection

1) Start the engine.

2) Inspect the fuel system for loose connections.

Note
Inspect for fuel leakage.
Fuel tank unit removal (RZ4E-TC)

1. Component views

Fuel tank unit

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Part name

1. Retainer ring
2. Fuel tank unit
3. Fuel tank unit seal
4. Fuel tank

Tightening torque

1: 125 N・m { 12.7 kgf・m / 92 lb・ft }

2. Fuel tube removal

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel tube removal".

3. Fuel tank unit removal

1) Remove the retainer ring from the fuel tank using the special tool.

Caution
Do not reuse the retainer ring.
Cover the retainer ring with a shop cloth, etc.
Breakage may occur if the special tool comes into contact with the ribbed bottom portion of the
retainer ring.

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SST: 5-8840-2990-0 - Wrench;Chain

2) Remove the fuel tank unit from the fuel tank.

Caution
The fuel tank unit seal cannot be reused.
Remove it gradually not to distort the float arm.
Cover the fuel tank to prevent foreign material from entering.
Fuel tank unit inspection (RZ4E-TC)

1. Fuel tank unit inspection

1. Airtight inspection

1) Connect the fuel filler hose to the filler neck and fuel tank.

2) Connect the breather hose to the filler neck and fuel tank.

3) Plug the return pipe connection outlet of the fuel tank unit.

4) Install the fuel filler cap to the filler neck.

Caution

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Tighten until it makes a clicking sound at least once.

5) Apply soapy water to the area around the fuel tank unit seal.

6) Apply air from the feed side pipe of the fuel tank unit to the fuel tank for 15 seconds or more to the specified
pressure.

34.3 kPa { 0.3 kgf/cm2 / 5 psi } Specified pressure

7) Verify that bubbles are not coming out around the fuel tank unit seal.

2. Resistance measurement

The fuel tank unit changes the internal resistance in accordance with the float position, which varies depending on
the fluid surface height, and operates the fuel meter indicator.

1) Move the float to each position and measure the resistance between the connector terminals using a DMM.
Legend

1. Positive side power supply terminal

2. Ground terminal

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Legend

a. Distance from bottom to E position

b. Distance from bottom to 1/4 position

c. Distance from bottom to 1/2 position

d. Distance from bottom to 3/4 position

e. Distance from bottom to F position

f. F position

g. 3/4 position

h. 1/2 position

i. 1/4 position

j. E position

Float Net
Distance Resistance
position volume
62.3 L
185.7 { 16.46
F mm { US gal
14 to 20 Ω
position 7.311 in / 13.70
} Imp.gal
}
47.0 L
148.5 { 12.42
3/4 mm { US gal 31.25 to
position 5.846 in / 10.34 37.25 Ω
} Imp.gal
}
 32.8 L
116.6 { 8.66
1/2 mm { US gal
42 to 48 Ω
position 4.591 in / 7.22
} Imp.gal
}
19.4 L
{ 5.12
85.9 mm
1/4 US gal 69.75 to
{ 3.382
position / 4.27 77.75 Ω
in }
Imp.gal
}
5.4 L {
1.43
33.3 mm
E US gal 140 Ω or
{ 1.311
position / 1.19 more
in }
Imp.gal
}

2) Connect the connector on the vehicle to the fuel tank unit and move the float.

3) Verify that the low fuel warning light illuminates when the float is at the E position.

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Note
Replace the fuel tank unit if a malfunction is found.
Fuel tank unit installation (RZ4E-TC)

1. Component views

Fuel tank unit

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Part name

1. Retainer ring
2. Fuel tank unit
3. Fuel tank unit seal
4. Fuel tank

Tightening torque

1: 125 N・m { 12.7 kgf・m / 92 lb・ft }

2. Fuel tank unit installation

1) Clean the seal surfaces of the fuel tank and fuel tank unit.

Caution
Keep the seal surface clean as foreign material on it causes fuel leakage.

2) Install the fuel tank unit seal to the fuel tank.

Note
Install along the groove of the fuel tank opening.

Caution
The fuel tank unit seal cannot be reused.

3) Align the fuel tank unit protrusions with the fuel tank depressions, and install the fuel tank unit to the fuel tank.

Caution
Install it gradually not to distort the float arm.

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4) Install the retainer ring to the fuel tank using the special tool.

Caution
Do not reuse the retainer ring.
Cover the retainer ring with a shop cloth, etc.
Breakage may occur if the special tool comes into contact with the ribbed bottom portion of the
retainer ring.

SST: 5-8840-2990-0 - Wrench;Chain

Tightening torque: 125 N・m { 12.7 kgf・m / 92 lb・ft }

 cardiagn.com
Legend

1. Ribbed bottom portion

5) Referring to the diagram, align the retainer ring alignment mark with the fuel tank side alignment mark.
 Legend

1. Alignment mark on the fuel tank side

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2. Alignment mark on the retainer side

3. Fuel tube installation

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel tube installation".

Fuel tube removal (RZ4E-TC)

1. Fuel tank removal

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel tank removal".

2. Fuel tube removal

1) Clean off any dirt adhered to the quick connector fitting of the fuel tube using air.

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2) Remove the fuel tube from the fuel tank unit.

Note
Hold the connector with one hand while pushing the release button of the quick connector and pull
out the connector with the other hand.
Legend

1. Release button

Caution
Do not use any tool.
The connector connection should be removed with bare hands.
Push and pull the connector using lubricating oil until the pipe connection is disconnected.

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Caution
Cover the removed connector with a plastic bag to prevent foreign material or water from entering.
Fuel tube inspection (RZ4E-TC)

1. Fuel tube inspection

1) Inspect the fuel tube for the following.

Damage
Dent
Cracking

Note
Replace the fuel tube if a malfunction is found.

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Fuel tube installation (RZ4E-TC)

1. Fuel tube installation

1) Install the fuel tube to the fuel tank unit.

Note
Applying engine oil or diesel oil to the pipe makes port installation easy.

Caution
Insert the connector straight in until it clicks.
Pull it out with the standard force and make sure that it is securely locked.

Standard: 49 N { 5.0 kg / 11 lb }

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2. Fuel tank installation

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel tank installation".

Injector removal (RZ4E-TC)

1. Component views

Injector

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Part name

1. Injector clamp
2. Bolt
3. Injector
4. Sleeve nut
5. Injector leak-off hose
6. Eyebolt
7. Fuel feed pipe
8. Fuel supply pump
9. Injection pipe
 10. Common rail (fuel rail)

Tightening torque

1: 38 N・m { 3.9 kgf・m / 28 lb・ft }

4: 35 N・m { 3.6 kgf・m / 26 lb・ft }

6: 20.2 N・m { 2.1 kgf・m / 15 lb・ft }

2. Engine cover removal

1) Remove the engine cover from the engine.

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Legend

1. Engine cover

3. Injection pipe removal

1) Clean the injector and injector bracket using an air blower.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution
Do not reuse the injection pipe.
4. Injector removal

1) Disconnect the connector from the injector.

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2) Remove the injector leak-off hose from the injector leak-off pipe and fuel leak-off pipe.

Legend

1. Injector leak-off hose

3) Remove the clip from the injector.

4) Remove the injector leak-off pipe from the injector.

Caution
Do not reuse the injector leak-off pipe or clip.
Legend

1. Clip

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2. Injector leak-off pipe
3. Injector

5) Remove the injector clamp from the injector.

Legend

1. Washer
2. Injector clamp

6) Clean the injector clamp bolt hole using an air blower.

Caution
Do not to allow the intrusion of foreign material.

7) Remove the injector from the cylinder head.

Note
Store the removed injectors with the cylinder numbers attached.
Caution
Cover the exposed portion to prevent foreign material from getting into the fuel system.
Do not damage the injector nozzle.
Never touch the electromagnetic section of the injector because it causes performance reduction and
breakage.

8) Remove the gasket from the injector.

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Legend

1. Injector
2. Gasket
Injector installation (RZ4E-TC)

1. Component views

Injector

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Part name

1. Injector clamp
2. Bolt
3. Injector
4. Sleeve nut
5. Injector leak-off hose
6. Eyebolt
7. Fuel feed pipe
8. Fuel supply pump
9. Injection pipe
 10. Common rail (fuel rail)

Tightening torque

1: 38 N・m { 3.9 kgf・m / 28 lb・ft }

4: 35 N・m { 3.6 kgf・m / 26 lb・ft }

6: 20.2 N・m { 2.1 kgf・m / 15 lb・ft }

2. Injector installation

1) Clean the injector bracket mounting bolt holes using an air blower.

Caution
Thoroughly clean to eliminate all sand and dust.

2) Clean the cylinder head installation surface and injector.

3) Install the gasket to the injector.

Note

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Push until seated evenly against the injector retaining nut section.

Caution
Do not press parts other than the gasket seal surface.

Legend

1. Gasket
2. Retaining nut section
3. Seal surface

4) Install the injector to the cylinder head.

Caution
Do not press the injector connector.
5) Apply engine oil to the following locations.

Threaded section of bolt

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Seat surface of the bolt
Washer contact surface on the injector clamp

6) Install the injector clamp to the injector.

Tightening torque: 38 N・m { 3.9 kgf・m / 28 lb・ft }

Legend

1. Washer
2. Injector clamp

7) Install the injector leak-off pipe to the injector.

8) Install the clips to the injector.

Legend

1. Clip

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2. Injector leak-off pipe
3. Injector

9) Connect the injector leak-off hose to the injector leak-off pipe and fuel leak-off pipe.

Legend

1. Injector leak-off hose

10) Connect the connector to the injector.

1. When replacing the injector

Erase the old cylinder number ID code on the Injector ID Code label attached to the cylinder head cover with a
black pen, etc.

Label on the cylinder head cover (Sample)

Legend

1. No. 1 cylinder Injector ID Code

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2. No. 2 cylinder Injector ID Code
3. No. 3 cylinder Injector ID Code
4. No. 4 cylinder Injector ID Code
5. Injector ID Code label

1) Record the Injector ID Code of the new injector.

Note
Record the 24 characters of the injector ID plate.

The correct order of the ID codes shown in the following injector illustration is as follows.
95 04 F9 F8 F0 00 F0 E7 09 F6 F9 96

Injector (Sample)

Legend

1. Injector ID Code
2. Injector
3. Injection pipe installation

1) Temporarily tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the
diagram.

Caution
Do not reuse the injection pipe.

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2) Final tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the diagram.

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

4. Engine cover installation

1) Install the engine cover to the engine.

Legend

1. Engine cover

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5. ECM setting

1. Injector ID Code programming

Note
If the injector has been replaced, perform the Injector ID Code programming and ECM learned value
clear.

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

Diagnostics
Engine
RZ4E
Programming
Injector ID Code
Program Injector ID Code

4) Program the Injector ID Code into the ECM by following the on-screen instructions.

5) After the programming is completed, turn the ignition switch OFF for 30 seconds.

2. ECM learned value clear

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

Diagnostics
 Engine
RZ4E
Actuator Test
Reset Small Fuel Injection Quantity Learning

4) Perform the ECM learned value clear by following the on-screen instructions.

5) After the learned value clear is complete, turn OFF the ignition switch for 30 seconds.

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Pressure limiter removal (RZ4E-TC)

1. Component views

Pressure limiter

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Part name

1. FRP sensor
2. Common rail (fuel rail)
3. Pressure limiter

Tightening torque

1: 35 N・m { 3.6 kgf・m / 26 lb・ft }

3: 172 N・m { 17.5 kgf・m / 127 lb・ft }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

 Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3. Fuel leak-off pipe removal

1) Disconnect the fuel leak-off hose from the fuel leak-off pipe.

2) Remove the fuel leak-off pipe from the common rail (fuel rail) and flywheel housing.

Caution
Cover the exposed section to prevent the intrusion of foreign material.

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Legend

1. Fuel leak-off pipe

4. Pressure limiter removal

1) Remove the pressure limiter from the common rail (fuel rail).
Legend

1. FRP sensor

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2. Common rail (fuel rail)
3. Pressure limiter
Pressure limiter installation (RZ4E-TC)

1. Component views

Pressure limiter

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Part name

1. FRP sensor
2. Common rail (fuel rail)
3. Pressure limiter

Tightening torque

1: 35 N・m { 3.6 kgf・m / 26 lb・ft }

3: 172 N・m { 17.5 kgf・m / 127 lb・ft }

2. Pressure limiter installation

1) Install the pressure limiter to the common rail (fuel rail).

Tightening torque: 172 N・m { 17.5 kgf・m / 127 lb・ft }

 Legend

1. FRP sensor

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2. Common rail (fuel rail)
3. Pressure limiter

3. Fuel leak-off pipe installation

1) Install the fuel leak-off pipe to the common rail (fuel rail) and flywheel housing.

Tightening torque: 20.2 N・m { 2.1 kgf・m / 15 lb・ft } Common rail (fuel rail) side

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Flywheel housing side

Legend

1. Fuel leak-off pipe

2) Connect the fuel leak-off hose to the fuel leak-off pipe.

4. Preliminary and post procedures

 1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

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Water sedimenter switch removal (RZ4E-TC)

1. Fuel filter removal

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel filter removal".

2. Water sedimenter switch removal

1) Remove the element case from the fuel filter body.

Caution
Do not reuse the O-ring or gasket.

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Legend

1. Element case
Water sedimenter switch inspection (RZ4E-TC)

1. Water sedimenter switch inspection

1. Operation inspection

1) Connect the connector to the water sedimenter switch.

2) Turn ON the ignition switch.

3) Turn the element case upside down, and move the float.

4) Check whether the warning light in the instrument panel cluster illuminates.

Caution

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If the indicator light does not illuminate, inspect the continuity of the water sedimenter switch.

2. Continuity inspection

1) Turn the element case upside down, and move the float.

2) Make sure there is continuity between the terminals of the water sedimenter switch connector using a DMM.

3) Disconnect the connector from the water sedimenter switch.

4) Verify that the warning light on the sedimenter illuminates when connected between the connector terminals on
the vehicle side.

Note
At this time, the circuit is normal if the sedimenter warning light lights up.
If a malfunction is found, replace the water sedimenter switch or repair poor connections or open
circuits between the circuits.
Legend

1. Water sedimenter switch

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2. Vehicle side connector
3. Harness
4. Drain valve
Water sedimenter switch installation (RZ4E-TC)

1. Water sedimenter switch installation

1) Install the element case to the fuel filter body.

Caution
Do not reuse the O-ring or gasket.

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Legend

1. Element case

2. Fuel filter installation

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel filter installation".

Supplementary Information (RZ4E-TC)

1. Component views

Fuel filter

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Part name

1. Pressure switch
2. Priming pump
3. Fuel feed hose (Fuel tank side)
4. Fuel filter
5. Fuel return hose
6. Fuel feed hose (Supply pump side)

Injector
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Part name

1. Injector clamp
2. Bolt
3. Injector
4. Sleeve nut
5. Injector leak-off hose
6. Eyebolt
7. Fuel feed pipe
8. Fuel supply pump
9. Injection pipe
10. Common rail (fuel rail)

Tightening torque

1: 38 N・m { 3.9 kgf・m / 28 lb・ft }

4: 35 N・m { 3.6 kgf・m / 26 lb・ft }

6: 20.2 N・m { 2.1 kgf・m / 15 lb・ft }

Common rail (fuel rail)

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Part name

1. Common rail (fuel rail)

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Pressure limiter
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Part name

1. FRP sensor
2. Common rail (fuel rail)
3. Pressure limiter

Tightening torque

1: 35 N・m { 3.6 kgf・m / 26 lb・ft }

3: 172 N・m { 17.5 kgf・m / 127 lb・ft }

Fuel supply pump

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Part name

1. Bolt
2. Fuel supply pump
3. O-ring
4. Nut
5. Bolt
6. Supply pump bracket
7. O-ring
8. Supply pump gear
9. Supply pump gear nut

Tightening torque

1: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

9: 63.7 N・m { 6.5 kgf・m / 47 lb・ft }

FRP regulator
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Part name

1. Bolt
2. FRP regulator
3. O-ring
4. Fuel supply pump

Tightening torque

1: 9.0 N・m { 0.9 kgf・m / 80 lb・in }

Fuel tank
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Part name

1. Fuel feed tube

2. Fuel tank
3. Fuel filler hose
4. Breather hose
5. Evaporator hose
6. Bolt
7. Fuel tank band
8. Fuel return tube
9. Fuel tank protector

Tightening torque

6: 68 N・m { 6.9 kgf・m / 50 lb・ft }

Fuel tank unit

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Part name

1. Retainer ring
2. Fuel tank unit
3. Fuel tank unit seal
4. Fuel tank

Tightening torque

1: 125 N・m { 12.7 kgf・m / 92 lb・ft }