ISUZU TF SERIES 2004 Workshop Manual

FUEL SYSTEM 6C – 11
5. Install the filler neck to the body with bolt.
6. Install the inner liner of the wheel house at rear left side.
7. Remove lifter from the fuel tank.
8.
Lower the vehicle.
9.
Tigten the filler cap until at least three clicks.
10.
Connect the battery ground cable.

6C – 12 FUEL SYSTEM
FUEL GAUGE UNIT
Fuel Gauge Unit and Associated Parts


RTW46CLF000501

Legend

1. Fuel Feed Port
2. Fuel Return Port

3. Fuel Emission Port

4. Fuel Gauge Unit and Sender Assembly

5. Connector; Fuel Gauge Unit


6. Fuel Tube/Quick Connector
7. Retainer Ring (Fuel Gauge Unit Lock)
8. Seal; Fuel Gauge Unit
9. Fuel Tank Assembly
10. Evapo Tube/Quick Connector

FUEL SYSTEM 6C – 13

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.

6C – 14 FUEL SYSTEM

8.
Check leak.
Methed of leak check.

(1)
Plug end of quick connector and breather hose (Pull of
f
the breather hose from fuel tank) and tighten fuel fille
r
cap until at least one click are heard.
(2)
Apply water soap around the fuel gauge unit seal area.
(3)
Pressure air into the fuel tank from end of breather pipe
at 5psi (34.3 kPa/2.8kgf/cm
2) over 15 seconds.
(4)
Verify no bubbles around the fuel gauge unit seal area.
9.
Install the fuel tank assembly (9).
NOTE: Refer to “Install the fuel tank” in this section.

FUEL SYSTEM 6C – 15
FUEL TUBE / QUICK – CONNECTOR FITTINGS



Precautions


Do not light a match or create a flame.


Keep flames away from your work area to preven
t
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.
When 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.

6C – 16 FUEL SYSTEM


140R100037

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




140R100028

Cover the connectors that was removed with a plastic bag,
to prevent dust or rain water from entering.




140R100036
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 o
f
rust, dent, scratch.


After cleaning the port, insert it straight into the connector
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.


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. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.

FUEL SYSTEM 6C – 17
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.

6C – 18 FUEL SYSTEM
FUEL FILLER CAP




RTW36CSH000401
Legend

(1)
Pressure Valve

(2)
Vacuum Valve

(3)
Seal Ring


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.


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
primarily for this application and must be replaced with
the same type or decreased engine performance may
occur.

FUEL SYSTEM 6C – 19
INJECTION PUMP

REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.



Removal
1. Battery
Remove the battery from the battery tray.



6C-1
2. Drive Belt 1) Loosen the adjust bolt of the power steering pump pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly


P1010003
4. Accelerator Control Cable
Disconnect the accelerator cable from the intake throttle.


5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the intake throttle.
6. Fan

6C – 20 FUEL SYSTEM

7. Power Steering Pump Bracket


6C-4 8. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Disconnect the harness connector from the throttle
position sensor.

9. Oil Level Gauge
10. Fuel Pipe
1) Disconnect the fuel hoses from the fuel filter or priming
pump.
2) Disconnect the fuel hoses from the injection pump.

11. Fuel Filter Assembly (Except EURO III model)
6C-5
12. Fuel Filter Bracket (Except EURO III model)
13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery
valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.

16. Intake Manifold
1) Remove the EGR valve from the intake manifold and
EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
17. Injection Pump Cover (4JA1TC/4JH1TC only)