Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 808

6C–5

ENGINE FUEL (6VD1 3.2L)

Fuel Pump

Fuel Pump and Associated Parts

060RW099

Legend

(1) Roll Over&Float Valve
(2) Fuel Gauge
(3) Fuel Tank Assembly

(4) Nut; Fuel Tank
(5) Fuel Pump Assembly
(6) Fuel Tank Cover
(7) Tank Cover Bolt

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 assembly (3) with

a lifter.

4. Remove fuel tank assembly (3). Refer to “Fuel Tank

Removal” in this section.

5. Remove fuel pump assembly (5).

NOTE: After removing pump assembly (7), cover fuel
tank to prevent any dust entering.

Installation

1. Install FPAS assembly (5).
2. Install fuel tank assembly (3). Refer to “Fuel Tank

Installation”.

3. Fill the tank with fuel and tighten fuel filler cap.
4. Connect battery ground cable.

6C–6

ENGINE FUEL (6VD1 3.2L)

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.

Fuel Tank

Fuel Tank and Associated Parts

060RW099

Legend

(1) Roll Over&Float Valve
(2) Fuel Gauge
(3) Fuel Tank Assembly

(4) Nut; Fuel Tank
(5) Fuel Pump Assembly
(6) Fuel Tank Cover
(7) Tank Cover Bolt

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 (3) with a lifter.
4. Disconnect evaporative fuel hose.

5. Disconnect fuel feed 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 and fuel filler hose at the

fuel filler neck.

NOTE: Cover fuel hose to prevent any dust entering.

7. Remove the tank cover bolts (7) and the fuel tank

cover (6), the six fuel tank assembly fixing nuts (4) of
the tank.

6C–7

ENGINE FUEL (6VD1 3.2L)

8. Let down the tank and disconnect the wiring

connectors.

9. Remove fuel tank assembly.

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

evaporative fuel hose and pipe.

11. Remove fuel pump along with the fuel hoses.

Installation

1. Install fuel pump (5).
2. Install roll over & float valve (1) by fitting in of the

retaining cover (2).

3. Lift up fuel tank assembly and connect the wiring

connectors (5,6).

4. Install fuel tank assembly along with the tank cover

and tighten the six fixing nuts to the specified torque.

Torque: 68 N·m (6.96thinsp;kg·m/50 lb ft)

5. Connect fuel filler hose and air breather hose, and clip

them firmly.

6. Connect fuel feed hose and fuel return hose, and clip

them firmly.

7. Connect evaporative fuel hose.
8. Tighten fuel filler cap.
9. Connect battery ground cable.

Fuel Gauge Unit

Removal and Installation

As for removal and installation of the Fuel Gauge Unit,
refer to  “Fuel Tank” of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender assembly.

Fuel Filler Cap

General Description

Fuel filler cap includes vacuum valve.
In case any high vacuum happen in tank, the valve works
to adjust the pressure to prevent the tank from being
damaged.

060RW098

Legend

(1) Vacuum Valve
(2) Fuel Filler Cap

Inspection

Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.

CAUTION: The fuel filler cap valve has
characteristics.
A defective valve, no valve at all or a valve with the
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.

6C–8

ENGINE FUEL (6VD1 3.2L)

Main Data and Specifications

Torque Specification

N·m (kg·m/ lb·ft)

060RW217