Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1705

ENGINE FUEL  6C-11

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 may still

have some pressure in it.

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.

Cover the connectors that was removed with a plastic bag,

to prevent dust or rain water from entering.

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 at 49N (5kgf) it out to

make sure that it is not drawn and is securely locked.

6C-12  ENGINE FUEL

Assembling Advice

By applying engine oil 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  “ON”  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.

Fuel Pump Relay

General Description

In order to control the FPAS operation, the FPAS relay is
provided. When the starter switch is turned to "ON" position,
the FPAS relay operates the FPAS for 2 seconds.
When it is turned to "START" position, the Engine Control
Module receives the reference pulse from the Ignition Control
Module and it operates the relay, again causing the FPAS to
feed fuel.

ENGINE FUEL  6C-13

Fuel Tank

Fuel Tank and Associated Parts

Legend

1 Roll Over&Float Valve (If applicable)

2 Hose; Evaporative Fuel (If applicable)

3 Hose; Air Breather

4 Hose; Fuel Filter

5 Fuel Pump and Sender Assembly

6 Fuel Tank Assembly

7 Hose; Fuel Delivery

8 Hose; Fuel Return

(2.2L & 2.0L Models)

(2.4L Model)

6C-14  ENGINE FUEL

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 fuel filler cap.

3. Support underneath of the fuel tank protector with a lifter.

4. Disconnect evaporative fuel hose at the canister.

5. Disconnect fuel delivery hose and fuel return hose near the

fuel filter.

NOTE: Plug both ends of the fuel hoses to prevent fuel
leakage.

6. Disconnect air breather hose (3) and fuel  filler  hose  (4)  at

the fuel filler neck.

NOTE: Cover fuel hose to prevent any dust entering.

7. Remove  the  four  fuel  tank  assembly  fixing  bolts  at  four

corners of the tank.

8. Let  down  the  tank  and  disconnect  the  wiring  connectors

and  the  emission  hose  at  the  emission  port  on  the  fuel

pump and sending assembly (5).

9. Remove fuel tank assembly along with protectors.

10. Remove roll over&float valve (1) along with the evaporative

fuel hose and pipe (2).

11. Remove  fuel  pump  and  sender  assembly  (5)  by  removing

the snap ring along with the fuel hoses (7, 8).

12. Remove tank protector by removing the fixing bolts.

Installation

1. Install  protectors  and  tighten  the  fixing  bolts  to  the

specified torque.

Torque; 68 N

⋅⋅⋅⋅m (6.9 kgf⋅⋅⋅⋅m)

2. Install fuel pump and sender assembly by fitting in the snap

ring.

3. Install roll over&float valve (1).

4. Lift up fuel tank assembly  and  connect  the  emission  hose

to the emission port and the wiring connectors on the  fuel

pump and sending assembly (5).

5. Install fuel tank assembly along with protectors and tighten

the four fixing bolts to the specified torque.

Torque: 68 N

⋅⋅⋅⋅m (6.9 kgf⋅⋅⋅⋅m)

6. Connect  fuel  filler  hose  (4)  and  air  breather  hose  (3),  and

clip them firmly.

7. Connect fuel delivery hose (7) and fuel return hose (8), and

clip them firmly.

8. Connect evaporative fuel hose (2).

9. Tighten fuel filler cap.

10. Connect battery ground cable.