engine ISUZU AXIOM 2002 Service Repair Manual

ENGINE COOLING (6VE1 3.5L)6B±13
Special Tool
ILLUSTRATIONTOOL NO.
TOOL NAME
J±24460±01
Tester; radiator cap
J±33984±A
Adapter; radiator cap

6C±1 ENGINE FUEL (6VE1 3.5L)
AXIOM
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution 6C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6C±2. . . . . . . . . . . . . . . . . . . . .
Fuel Metering 6C±3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In±Tank Fuel Filter 6C±5. . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test 6C±5. . . . . . . . . . . . . . . . . . .
Fuel Pump 6C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts 6C±6. . . . . . . .
Removal 6C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tube / Quick ± Connector Fittings 6C±8. . . . .
Precautions 6C±8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions During Work 6C±8. . . . . . . . . . . . . . . . . . Removal 6C±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of Quick±Connector 6C±9. . . . . . . . . . . . .
Assembling Advice 6C±9. . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6C±10. . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C±10. . . . . . . . . . . . . . . . . . . .
Fuel Tank 6C±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank and Associated Parts 6C±10. . . . . . . . .
Removal 6C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6C±12. . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 6C±12. . . . . . . . . . . . . . .
Fuel Filler Cap 6C±12. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C±12. . . . . . . . . . . . . . . . . . . .
Inspection 6C±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6C±13. . . . . . . . . . . . .
Special Tool 6C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6C±2
ENGINE FUEL (6VE1 3.5L)
General Description
140R200004
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump and Sender Assembly
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank
(8) Fuel Rail Left
(9) Left Bank(10) Fuel Pressure Control Valve
(11) Common Chamber
(12) Duty Solenoid Valve
(13) Throttle Valve
(14) Canister
(15) Vent Hose
(16) Vent Solenoid Valve
(17) Separator
(18) Shut off Valve (With Over Pressure Relief
Valve)

6C±3 ENGINE FUEL (6VE1 3.5L)
When working on the fuel system, there are several
things to keep in mind:

Any time the fuel system is being worked on,
disconnect the battery ground cable except for those
tests where battery voltage is required.

Always keep a dry chemical (Class B) fire
extinguisher near the work area.

Replace all pipes with the same pipe and fittings that
were removed.

Clean and inspect ªOº rings. Replace if required.

Always relieve the line pressure before servicing any
fuel system components.

Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.

Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper
emission control system operation.
Its use will also minimize spark plug fouling and extend
engine oil life. Using leaded gasoline can damage the
emission control system and could result in loss of
emission warranty coverage.
The vapor pressure sensor and vent solenoid valve for
vapor pressure sensor are used to detect abnormalities in
the evaporative emission control system.
The PCM decides whether there is an abnormality in the
evaporative emission control system based on vapor
pressure sensor signal.Fuel Metering
The Powertrain Control Module (PCM) is in complete
control of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is used
only to let air into the engine. The fuel is injected by
separate injectors that are mounted over the intake
manifold.
The Manifold Absolute Pressure (MAP) sensor measures
the changes in the intake manifold pressure which result
from engine load and speed changes, which the MAP
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the engine.
The changing voltage is transformed into an electric
signal and provided to the PCM.
With receipt of the signals sent from the MAP sensor,
Intake Air Temperature sensor and others, the PCM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
affect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaft
revolution. The PCM controls the injector on time so that
the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable ªOº rings are used on the injector
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weather
operation.
The fuel pressure control valve that is mounted on the fuel
rail maintains a pressure differential across the injectors
under all operating conditions. It is accomplished by
controlling the amount of fuel that is recirculated back to
the fuel tank based on engine demand.
See Section ªDriveability and Emissionº for more
information and diagnosis.

6C±4
ENGINE FUEL (6VE1 3.5L)
Fuel Filter
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section ªDriveability and Emissionº.
1. Disconnect battery ground cable.
2. Remove Fuel filler cap(1).
140R100023
Legend
(1) Fuel Filler Cap
(2) Receive Rubber Drain
3. Disconnect fuel hoses(1) from fuel filter on both
engine side and fuel tank side.
4. Fuel filter fixing bolt(2).

Remove the fuel filter fixing bolt(2) on fuel filter
holder.5. Remove fuel filter(3).
041RW003
Legend
(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt or sediment.
3. Check clogged drain port of the receive rubber by the
foreign material, repair or clear if found clog it.

6C±5 ENGINE FUEL (6VE1 3.5L)
Installation
1. Install the fuel filter in the proper direction.
2. Install fuel filter holder fixing bolt.
3. Connect fuel hoses on engine side(1) and fuel tank
side(2).
041RW001
4. Install fuel filler cap
5. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel leakage.
In±Tank Fuel Filter
The filter is located on the lower end of fuel pickup tube in
the fuel tank. The fuel filter prevents dirt and water the fuel
system not unless the filter is submerged in water. The
fuel filter is maintenance free, that requires no
maintenance. Excess water and sediment in the tank
restricts fuel supply to the engine, resulting in engine stall.
If this happens, the fuel tank would need to be cleaned
thoroughly.
Fuel Pump Flow Test
If reduction of fuel supply is suspected, perform the
following checks.
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe and
hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, inspect bent or kink fuel pipes and hoses.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.
4. Connect the pump relay terminals with a jumper
wire(1) as shown and start the fuel pump to measure
delivery.
140R200003
CAUTION: Never generate sparks when connecting
a jumper wire.
Delivery Times
Delivery
15 seconds0.38 liters minimum
If the measure value is out of standard, conduct the
pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E
ªFuel Control Systemº.

6C±6
ENGINE FUEL (6VE1 3.5L)
Fuel Pump
Fuel Pump and Associated Parts
140R200008
Legend
(1) Fuel Feed Port
(2) Fuel Tube/Quick Connector
(3) Fuel Return Port
(4) Fuel Pump and Sender (FPS) Assembly(5) Connector; Fuel Feed Pump
(6) Connector; Fuel Tank Pressure Sensor
(7) Retainer (Fuel Pump Lock)
(8) Fuel Tank Assembly
(9) Seal; Fuel Pump
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section ªDriveability and Emissionº.
1. Remove fuel tank assembly(8). Refer to ªFuel Tank
Removalº in this section.
2. Remove Fuel Tube/Quick Connector (2).
NOTE: Refer to ªFuel Tube/Quick Connector Fittingsº in
this section when performing any repairs.

6C±7 ENGINE FUEL (6VE1 3.5L)
3. Remove the retainer (7) with tool J±39765 and
remove the fuel pump and sender (FPS) assembly
(4).
140R200007
NOTE: After removing pump assembly (4), cover fuel
tank to prevent any dust entering.
Installation
1. Install FPS assembly(4) with retainer (7) and new
seal; fuel pump (9) by J±39765.
2. Install Fuel Tube/Quick Connector (2).
NOTE: Refer to ªFuel Tube/Quick Connector Fittingsº in
this section when performing any repairs.
3. Install fuel tank assembly(8). Refer to ªFuel Tank
Installationº.

6C±8
ENGINE FUEL (6VE1 3.5L)
Fuel Tube / Quick ± Connector Fittings
Precautions

Do not light a match or create a flame.

Keep flames away from your work area to prevent
flammable materials from catching fire.

Disconnect battery ground cable to prevent electrical
shorts.

Pre-treat piping system or associated parts from
thermal damage or from spattering when welding or
similar heat-generating work.
Cautions During Work
140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
NOTE: An O-ring inside the quick connector
provides the seal between the quick
connector and the port. Be careful not to
damage the mating surfaces and O-ring
when attaching the connector. Do not allow
foreign material to enter the connector or the
port.
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electrolyte.
Piping that has been splattered with battery electrolyte or
battery electrolyte soaked cloth that was wiped on the
piping cannot be used.
Removal
1. Open the fuel cap to relieve the fuel pressure in the
tank.
Use compressed air to remove any dirt on the fuel
quick connect fittings prior to disconnecting the
fittings.
141R100002When disconnecting the fuel pipe, cover the area with
a cloth to prevent fuel from splashing as the fuel pipe
may still have some pressure in it.
2. For removal of the quick connector, pull out the
connector with the other hand while pressing the
square relieve button of the connector, as illustrated.
140R200001

6C±9 ENGINE FUEL (6VE1 3.5L)
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light
oil) and/or push and pull the connector until the pipe is
disconnected.
Cover the connectors that was removed with a plastic
bag, to prevent dust or rain water from entering.
140R100028
Reuse of Quick±Connector

Replace the port and connector if scratch, dent or
crack is found.

Remove any dirt build up on the port when installing
the connector. Replace the connector, if there is any
forms of rust, dent, scratch.

After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling it out
to make sure that it is not drawn and is securely
locked.
140R100036
Assembling Advice
By applying engine oil or light oil to the pipe, port makes
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dust from
sticking to the pipe surface ± which may decrease sealing
ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the ªONº position and listen for
pump start-up sound. Inspect for leaks, the fuel
pressure will increase as the fuel pump is actuated.
3. Perform leak inspection (step 2) several times.
4. Start the engine and observe the engine idle speed.
The presence of dirt in the fuel system may affect the
fuel injection system.