fuel tank removal ISUZU KB P190 2007 Workshop Repair Manual

SECTION 6C
FUEL SYSTEM


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 2
General Description ...................................................................................................... 6C - 3
Fuel Flow.................................................................................................................... 6 C - 3
Fuel Filter and Water Separator ............................................................................... 6C - 4
Injection Pump........................................................................................................... 6C - 6
Injection Nozzle ......................................................................................................... 6C - 7
Fuel Tank...................................................................................................................... .. 6C - 8
Removal .................................................................................................................... 6 C - 9
Installation ................................................................................................................ 6C - 9
Fuel Gauge Unit ............................................................................................................. 6C - 11
Removal ..................................................................................................................... 6 C - 12
Installation ................................................................................................................. 6C - 12
Fuel Tube / Quick - Connector Fittings........................................................................ 6C - 14
Filler Neck .................................................................................................................... .. 6C - 16
Removal ..................................................................................................................... 6 C - 16
Installation ................................................................................................................. 6C - 16
Fuel Filler Cap................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6 C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal ..................................................................................................................... 6C - 18
Installation ................................................................................................................. 6 C - 21
Injection Nozzle (4JA1L) ............................................................................................... 6C - 25
Disassembly .............................................................................................................. 6C - 25
Reassembly ............................................................................................................... 6C - 26
Special tools .................................................................................................................. 6C - 37
FU
EL SY STEM 6C – 1

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ISUZU KB P190 2007

FUEL SYSTEM 6C – 9
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 “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change
the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dust
entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house at rear left side.
6. Remove fixing bolt of the filler neck from the body.
7. Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering
and fuel leakage.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the tank band (2).
9. Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10. Lower the fuel tank (5).
NOTE: W hen lower the fuel tank from the vehicle, don’t scratch
each hose and tube by around other parts.













Installation
1. Raise the fuel tank.
NOTE: W hen raise the fuel tank to the vehicle, don’t scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected against
stopper.
3. Install the tank band and fasten bolt.
Torque N·m (kg·m / lb ft)
68 (6.9 / 50)
NOTE: The anchor of the tank band must be certainly installed
to guide hole on frame.
4. Connect the quick connector of the fuel tube to the fuel pipe and the evapo tube from evapo joint connector.
NOTE: Pull off the left checker on the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.

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ISUZU KB P190 2007

6C – 12 FUEL SYSTEM

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 “Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to “Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from fuel gauge unit.



140R100035
3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4. Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5. Discard fuel gauge unit seal (8) because it cannot be
reusable.


Installation
1. Clean the seal surface of the fuel tank and the fuel gauge unit.
NOTE: If there is dust on the seal surface, it becomes cause o
f
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.


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ISUZU KB P190 2007

6C – 14 FUEL SYSTEM
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 simila
r
heat-generating work.




140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube


Cautions During Work
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.





141R100002
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.
W hen disconnecting the fuel pipe, cover the area with a
cloth to prevent fuel from splashing as the fuel pipe ma
y
still have some pressure in it.


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ISUZU KB P190 2007

6C – 16 FUEL SYSTEM
FILLER NECK
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck assembl
y
is restored.
• Each joint area of the hose (to restore axial direction and
insertion length of the hose)
• Each fasten area of the clamp (to restore axial direction
and position of the clamp)
• Each bolt in the clamp (to restore fasten length of bolt in
the clamp)
• The band clip (to restore position and fasten length o
f
the band clip)
NOTE: Cover end of each hose and pipe to prevent any dust
entering.










Installation
1. Align each marking and restore the following point.
• Each joint area of the hose (Restore axial direction and
insertion length of the hose)
• Each fasten area of the clamp (Restore axial direction
and position of the clamp)
• Each bolt in the clamp (Restore fasten length of bolt in
the clamp)
Torque N·m (kg·m / lb ft)
2.5 (0.25 / 21.7)
filler neck side except flat deck model.
• The band clip (Restore position and fasten length of the
band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.



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FUEL SYSTEM (4JK1/4JJ1) 6C-1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS

Fuel System ....................................................... 6C-2 Service Precautions ........................................ 6C-2
Trouble Shooting ............................................. 6C-8
Fuel System Check ......................................... 6C-10
Fuel Filter Assembly ........................................... 6C-12 Components .................................................... 6C-12
Removal .......................................................... 6C-12
Installation ....................................................... 6C-12
Fuel Filter Cartridge............................................ 6C-13 Removal .......................................................... 6C-13
Installation ....................................................... 6C-13
Fuel Injector........................................................ 6C-14 Components .................................................... 6C-14
Removal .......................................................... 6C-15
Installation ....................................................... 6C-15
Torque Specifications...................................... 6C-18
Fuel Rail Pressure Sensor ................................. 6C-19 Removal .......................................................... 6C-19
Installation ....................................................... 6C-19
Fuel Pressure Limiter ......................................... 6C-20 Removal .......................................................... 6C-20
Installation ....................................................... 6C-20
Fuel Rail Assembly............................................. 6C-21 Components .................................................... 6C-21
Removal .......................................................... 6C-22
Disassembly .................................................... 6C-24
Reassembly..................................................... 6C-24
Installation ....................................................... 6C-24
Torque Specifications...................................... 6C-26
Fuel Supply Pump .............................................. 6C-27 Components .................................................... 6C-27
Removal .......................................................... 6C-28
Installation ....................................................... 6C-33
Torque Specifications...................................... 6C-38
Fuel Sedimenter Switch ..................................... 6C-39 Inspection ........................................................ 6C-39
Fuel Tank and Fuel Cooler ................................. 6C-40 Fuel Tank and Associated Parts ..................... 6C-40
Removal .......................................................... 6C-41
Installation ....................................................... 6C-41

Fuel Gauge Unit ................................................. 6C-42 Fuel Gauge Unit and Associated Parts ........... 6C-42
Removal .......................................................... 6C-43
Installation ....................................................... 6C-43
Special Tool .................................................... 6C-43
Fuel Tube/Quick-Connector Fittings .................. 6C-44 Precautions ..................................................... 6C-44
Cautions During W ork ..................................... 6C-44
Removal .......................................................... 6C-44
Reuse of Quick-Connector.............................. 6C-45
Assembling Advice .......................................... 6C-45
Filler Neck .......................................................... 6C-46 Removal .......................................................... 6C-46
Installation ....................................................... 6C-46
Fuel Filler Cap .................................................... 6C-47 General Description ........................................ 6C-47
Inspection ........................................................ 6C-47

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6C-2 FUEL SYSTEM (4JK1/4JJ1)
Fuel System
Service Precautions
Parts of the fuel system such as the internal part of the
fuel injector, and holes and clearances that form
passages for fuel are finished to a very high degree o
f
accuracy. They are therefore highly sensitive to foreign
matter and the entry of foreign matter could cause
damage to the fuel passage. Therefore, effective
measures should be taken to prevent the entry o
f
foreign matter.
If a water removal agent is used in the fuel then it will
absorb moisture in the light oil and may cause rust.
Therefore, do not use a water removal agent in the fuel
tank.
W hen servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/o
r
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with ne
w
ones.

Work procedure
•
The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, afte
r
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage afte
r
starting the engine.

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FUEL SYSTEM (4JK1/4JJ1) 6C-41
Removal
Note: W hen repairs to the fuel system have been
completed, start the engine and check the fuel system
for loose connections or leakage. For the fuel system
diagnosis, see Section "Drivability and Emission".
1. Disconnect the battery ground cable.
2. Slowly loosen the fuel filler cap.
Note: Be careful that fuel does not spout out because o
f
change of pressure in the fuel tank.
Note: Cover opening of the filler neck to prevent an
y
dust entering. 3. Jack up the vehicle.
4. Disconnect the quick connector (5) of the fuel tube at the fuel cooler way.
5. Remove fuel return hose (8) from the pipe.
6. Remove fixing bolt (7) of the bracket fuel coole
r
and remove bracket fuel cooler (6).
Note: Cover the opening of the pipe to prevent any dust
and fuel leakage.
Note: For remove fuel cooler, Remove bolts (10) of the
fuel cooler and remove fuel cooler.
7. Support underneath of the fuel tank with a lifter.
8. Remove the inner liner of the wheel house at rea
r
left side.
9. Remove fixing bolt of the filler neck from the body.
10. Disconnect the quick connector (5) of the fuel tube from the fuel pipe and the evapo tube from evapo
joint connector.
Note: Cover the quick connector to prevent any dust
entering and prevent fuel leakage.
Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs.
11. Remove fixing bolt (1) of the tank band and remove the tank band (2).
12. Disconnect the pump and sender connector on the fuel pump and remove the harness from the weld
clip on the fuel tank.
13. Lower the fuel tank (3).
Note: W hen lowering the fuel tank from the vehicle, do
not scratch the hoses and tubes by contact with othe
r
parts.

Installation
1. Raise the fuel tank.
Note: W hen raising the fuel tank to the vehicle, do not
scratch the hoses and tubes by contact with other parts.
2. Connect the pump and sender connector to the fuel pump and install the harness to the weld clip
on the tank.
Note: The connector must be securely connected
against the stopper.
3. Install the tank band and fasten bolt.
Torque: 68 N ⋅
⋅⋅
⋅
m (6.9 kg ⋅
⋅⋅
⋅
m /50 lb ft)
Note: The anchor of the tank band must be securely
installed to the guide hole on the frame.
4. Connect the quick connector of the fuel tube to the fuel pipe and the evapo tube from evapo joint
connector.
Note: Pull off the left checker on the fuel pipe.
Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs.
5. Install the filler neck to the body with bolt.
Note: For install the fuel cooler to the bracket with bolt.
Torque: 6.5 N ⋅
⋅⋅
⋅
m (0.7 kg ⋅
⋅⋅
⋅
m /61 lb in)
6. Install the bracket to Frame with bolt. Torque: 48 N ⋅
⋅⋅
⋅
m (4.9 kg ⋅
⋅⋅
⋅
m /35 lb ft)
7. Install the fuel return hose at the fuel cooler way.
8. Install the quick connector at the fuel cooler way.
9. Install the inner liner of the wheel house at rear left side.
10. Remove lifter from the fuel tank.
11. Lower the vehicle.
12. Tighten the filler cap until at least three clicks.
13. Connect the battery ground cable.



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FUEL SYSTEM (4JK1/4JJ1) 6C-43
Removal
Note: W hen repairs to the fuel system have been
completed, start the engine and check the fuel system
for loose connections or leakage. For the fuel system
diagnosis, see Section "Drivability and Emission".
1. Remove the fuel tank assembly (8). Refer to "Fuel Tank Removal" in this section.
2. Disconnect the quick connector (1) of the fuel tube from the fuel gauge unit.






140R100035
3. Remove the retainer ring (3) from the fuel tank
with the removal tool 5-8840-2602-0.
4. Slowly remove the fuel gauge unit (6) from the fuel tank as no bend float arm.
Note: Cover opening for the fuel gauge unit on the fuel
tank to prevent any dust entering.
5. Discard the fuel gauge unit seal (7) because it cannot be reused.

Installation
1. Clean the seal surface of the fuel tank and the fuel
gauge unit.
Note: If there is dust on the seal surface, it can cause a
fuel leak.
2. Install the new fuel gauge unit seal (7) to the opening of the fuel tank along the groove.
3. Slowly install the fuel gauge unit (6) into the fuel tank so there is no bend in the float arm.
4. Set the flange of the fuel gauge unit on the fuel gauge unit seal as mating convexity of the fuel
gauge unit and reentrant of the fuel tank.
5. Slowly lock the retainer ring (3) to the fuel tank with the remover tool 5-8840-2602-0.
6. Connect the quick connector (1) of the fuel tube to the gauge unit.
Note: Pull off the left checker of the fuel pipe.
Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs.
7. Check for leak. Method of leak check.
1. Plug the end of the quick connector and breather hose (Pull off the breather hose from
fuel tank) and tighten fuel filler cap until at least
one click is heard.
2. Apply soapy water around the fuel gauge unit seal area.
3 Pressure air into the fuel tank from the end o
f
the breather pipe at 34.3 kPa (0.35 kg / cm2 / 5
psi) over 15 seconds.
4 Verify that no bubbles from around the fuel gauge unit seal area.
8. Install the fuel tank assembly (8).
Note: Refer to "Install the fuel tank" in this section.



Special Tool


ILLUSTRATION PART NO.
PART NAME

5-8840-2602-0
Remover: fuel pump retainer ring


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6C-44 FUEL SYSTEM (4JK1/4JJ1)
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 the battery ground cable to prevent
electrical shorts.
• Pre −treat the piping system or associated parts
from thermal damage or from spattering when
welding or similar heat −generating work.

Cautions During Work
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.






140R100032
Legend
1. O-ring
2. Port
3. Connector
4. Plastic Tube


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. W hen 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.





140R100002
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connecto
r
with the other hand while pressing the square
release button of the connector, as illustrated.


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ISUZU KB P190 2007