ISUZU AXIOM 2002 Service Repair Manual

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.

6C±10
ENGINE FUEL (6VE1 3.5L)
Fuel Pump Relay
General Description
In order to control the fuel pump and sender (FPS)
operation, the FPS relay is provided. When the starter
switch is turned to ªONº position, the FPS relay operates
the FPS for 2 seconds.
When the key is turned to ªSTARTº position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPS to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
140R200006
Legend
(1) Fuel Tank Assembly
(2) Fuel Tank Fixing Bolt (QTY: 5)
(3) Fuel Tank Fixing Nut (QTY: 1)
(4) Separator Fixing Bolt (QTY: 2)
(5) Fuel Filler Hose(6) Fuel Vent Hose
(7) Fuel Feed Hose
(8) Fuel Return Hose
(9) Vapor Pressure Sensor Connector
(10) Fuel Feed Pump Connector

6C±11 ENGINE FUEL (6VE1 3.5L)
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. Drain the fuel from the fuel tank, refer to the ªFuel
Pump Flow Testº in this section.
2. Disconnect battery ground cable.
3. Loosen fuel filler cap to reduce the pressure in fuel
tank.
4. Support underneath of the fuel tank assembly (1) with
a lifter.
5. Disconnect fuel feed hose (7) and fuel return hose (8)
near the fuel filter.
NOTE: Plug both ends of the fuel hoses to prevent fuel
leakage.
6. Disconnect fuel filler hose (5) and fuel vent hose (6) at
the fuel filler neck.
NOTE: Cover fuel hoses to prevent any dust entering.
7. Remove two bolts (4) and remove separator.
8. Remove the five fuel tank assembly fixing bolts (2)
and one nut (3).
9. Lower the tank and disconnect the wiring connectors
(9, 10).
Installation
1. Raise the fuel tank assembly (1) and connect the
wiring connectors (9, 10).
2. Install fuel tank assembly along with protectors and
tighten the five fixing bolts (2) and one nut (3) to the
specified torque.
Torque: 68 N´m (50 lb ft)
3. Install the separator and tighten two bolts (4).
Torque: 10 N´m (95 lb in)
4. Connect fuel filler hose (5) and fuel vent hose and clip
them firmly.
5. Connect fuel feed hose (7) and fuel return hose(8),
and clip them firmly.
6. Tighten fuel filler cap until at least three clicks are
heard.
7. Connect battery ground cable.

6C±12
ENGINE FUEL (6VE1 3.5L)
Fuel Gauge Unit
Removal and Installation
Refer to ªFuel Pumpº in this section for removal and
installation of the Fuel Gauge Unit, since the fuel gauge
unit is linked to the fuel pump and sender assembly.
Fuel Filler Cap
General Description
A vacuum valve and pressure valve are built into the fuel
filler cap which adjusts the fuel pressure in the fuel tank to
prevent fuel tank damage.
140R100029
Legend
(1) Vacuum Valve
(2) Pressure Valve
(3) Seal Ring
Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective.
CAUTION:
A replacement fuel filler cap must be the same as the
original. The fuel filler cap valve was designed pri-
marily for this application and must be replaced with
the same type or decreased engine performance may
occur.

6C±13 ENGINE FUEL (6VE1 3.5L)
Main Data and Specifications
Torque Specification
140R200023
Special Tool
ILLUSTRATIONTOOL NO.
TOOL NAME
J±39765
Remover; fuel pump
retainer