fuel tank removal ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 766 of 4264
8A-108 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION
FUEL PUMP
Removal
1. Remove the fuel tank.
Refer to the Section 6C-ENGINE FUEL of this Manual.
Disconnect the fuel pipe.
Installation
Follow the removal procedure in the reverse order to install the
fuel pump.
Pay close attention to the important points mentioned in the
following paragraphs.
Rubber Seal
Be absolutely sure that the fuel pump rubber seals correctly
seated.
Connector
Be absolutely sure that the fuel pump connector is securely
connected.
This will prevent a poor contact and an open circuit.
Page 921 of 4264
ELECTRICAL-BODY AND CHASSIS 8A-263
WARNING LIGHT BULB, INDICATOR
LIGHT BULB AND ILLUMINATION LIGHT
BULB
Removal
Turn the bulb socket counterclockwise and pull the bulb out.
Installation
To Install, follow the removal steps in the reverse order.
FUEL TANK UNIT
Removal
Dismount the fuel tank first, then remove the fuel tank unit.
1. Remove the rear inner liner -LH
Remove the clip
2. Remove the filler neck.
Remove the screw
3. Remove the ground with cable.
4. Remove the fuel tank band.
T/M jack unit on the vehicle.
Disconnect fuel line quick connectors.
5. Remove the fuel tank unit from the fuel tank.
Page 922 of 4264
8A-264 ELECTRICAL-BODY AND CHASSIS
Installation
Rubber Seal
Be absolutely sure that the fuel tank unit rubber seal is
correctly seated.
Connector
Be absolutely sure that the fuel tank unit connector is securely
connected.
This will prevent a poor contact and an open circuit.
VEHICLE SPEED SENSOR (INSTALLED
ON THE TRANSMISSION)
Removal
1. Disconnect the connector.
2. Remove the vehicle speed sensor body by rotating it.
Installation
To Install, follow the removal steps in the reverse order, noting
the following point.
Tighten the vehicle speed sensor to the specified torque.
Vehicle Speed Sensor Tightening Torque Nm (kgfm/lb.ft)
25 4.9 (2.5 0.5/18 3.6)
Page 1301 of 4264
FUEL SYSTEM 6C – 1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 3
General Description....................................................................................................... 6C - 4
Fuel Flow .................................................................................................................... 6C - 4
Fuel Filter and Water Separator ............................................................................... 6C - 5
Injection Pump ........................................................................................................... 6C - 7
Injection Nozzle ......................................................................................................... 6C - 8
Fuel Tank ........................................................................................................................ 6C - 9
Removal ..................................................................................................................... 6C - 9
Installation ................................................................................................................. 6C - 10
Fuel Pump ...................................................................................................................... 6C - 12
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Fuel Tube / Quick - Connector Fittings ........................................................................ 6C - 14
Filler Neck ...................................................................................................................... 6C - 16
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Fuel Filler Cap ................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21
Page 1310 of 4264
6C – 10 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. 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 dus
t
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: When 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: When 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 agains
t
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.
Page 1313 of 4264
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.
Page 1315 of 4264
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.
Page 1317 of 4264
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.
Page 1873 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-49
Engine Assembly
Removal
P1010068
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood
to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Remove the ECM.
Disconnect the two connectors from the ECM.
. Remove fixing bolts on the common chamber.
Remove fixing bolts for ground cable.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (lef
t
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
f
front axle and remove transmission harness
bracket from engine left side.
14. Disconnect ground cable between engine and
frame.
15. Disconnect bonding cable connector on the back
of right dash panel.
16. Disconnect bonding cable terminal on the lef
t
bank.
17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
23. Move drive belt tensioner to loose side using
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side
of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side o
f
transmission.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts
from engine mount on chassis side.
36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are
different between the manual transmission and the
automatic transmission. Otherweise, the
transmission may be damaged.
Page 1943 of 4264
ENGINE FUEL (6VE1 3.5L) 6C-1
ENGINE
ENGINE FUEL (6VE1 3.5L)
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-4
Inspection............................................................. 6C-4
In-Tank Fuel Filter............................................... 6C-4
Fuel Pump Flow Test......................................... 6C-4
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-11
Fuel Tank and Associated Parts....................... 6C-11
Removal................................................................ 6C-11
Installation............................................................. 6C-12
Filler Neck................................................................ 6C-13
Removal................................................................ 6C-13
Installation............................................................. 6C-13
Fuel Gauge Unit...................................................... 6C-13
Removal and Installation.................................... 6C-13
Fuel Filler Cap......................................................... 6C-14
General Description............................................ 6C-14
Inspection............................................................. 6C-14
Main Data and Specifications................................ 6C-15
Special Tool.......................................................... 6C-16
Service Precaution
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 negative battery 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 “O" rings. Replace i
f
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.
All cars are equipped with an Evaporative Emission
Control System. The purpose of the system is to
minimize the escape of fuel vapors to the
atmosphere.