Isuzu engine C22NE / 22LE / 20LE. Manual - part 110

DRIVEABILITY AND EMISSIONS  6E1-269

FUEL PUMP RELAY

Removal

1.  Remove the fuse and relay box cover located right side

of engine room.

2.  Determine correct relay by referring to the diagram on the

cover.

3.  Insert a small screwdriver or use thumb pressure to

release the retainer of the relay.

4.  Pull the relay straight up and out of the fuse and relay

box.

Installation

1.  Insert the relay into the correct place in the fuse and relay

box with the catch slot aligned to retainer.

2.  Press down until the catch of retainer engages.

3.  Install fuse and relay box cover.

FUEL RAIL ASSEMBLY

Removal

Notice:

•

Use care when removing the fuel rail assembly in order
to prevent damage to the injector al connector terminal
and the injector spray tips.

•

Fitting should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passage.

Important: An eight-digit identification number is stamped on
side of the fuel injector. Refer to this number when you service
the fuel rail or when a replacement part is required.

1.

Disconnect 4 injector connectors.

2.  Lift side-clip up on the fuel rail.

3.  Disconnect fuel pressure regulator hose.

4.  Disconnect wiring harness from the bands on the fuel rail.

5.  Remove the intake pipe.

6.  Loosen flare nut.

A Lift up the injectors carefully to separate them from

intake manifold.

B  Lift up the fuel rail with injectors as assembly. Do not

separate the fuel injectors from fuel rail.

C  If an injector become separated from fuel rail, injector

backup O-ring and injector retainer clip must be
replaced.

D  Drain residual fuel from fuel rail into an approved

container.

6E1-270  DRIVEABILITY AND EMISSIONS

7.  If removal of fuel pressure regulator is necessary, Refer

to Fuel Pressure Regulator Removal Procedure.

8.  If removal of fuel injector is necessary, Refer to Fuel

Injectors Removal Procedure.

Installation

1.  Install the fuel injectors if necessary. Refer to Fuel

Injector Installation Procedure.

2.

Install the fuel pressure regulator if necessary. Refer to
Fuel Pressure Regulator Installation Procedure.

3.  Place the fuel injector rail assembly on the manifold and

insert the injectors into each port by pushing fuel rail.

4.

Install two fuel rail retaining bolts. Tighten fuel rail
retaining bolt to 19 N

⋅m (1.9kgf⋅m)

5.  Place wiring harness in its place and secure it with two

nuts.

6.  Connect all connector to each fuel injector.

7.  Connect the fuel supply line securely. Do not over tighten.

8.  Connect the fuel return line securely. Do not over tighten.

9.  Connect the negative battery cable.

10.  Crank the engine until it starts. Cranking the engine may

take longer than usual due to trapped air in the fuel
system. Check for leak. If fuel leak is observed, stop
engine immediately. Before correcting fuel leak, be sure
to depressurize system again.

DRIVEABILITY AND EMISSIONS  6E1-271

FUEL TANK

Removal

1.  Disconnect the negative battery cable.

2.  Remove fuel filler cap.

3.  Drain the fuel from fuel filler neck.

4.  Disconnect the fuel filler hose at the fuel tank.

5.  Disconnect the air breather hose at the fuel tank.

6.  Disconnect the evaporator hose at the fuel tank.

7.  Hold entire fuel tank at the bottom with stands.

8.  Disconnect fuel supply lines and fuel return line at near

the fuel filter inside of body frame.

9.  Remove fixing bolts holding fuel tank to the frame.

10.  Lower tank assembly from the vehicle a little to make

access space on top.

11.  Disconnect connectors at fuel pump.

12.  Remove pump tank assembly from the vehicle.

13.  Remove the tank under guard to the tank.

14.  Remove the tank from the guard.

Installation

1.  Secure fuel tank into under guard with retaining bolts, if

necessary.

2.  Place the fuel tank assembly onto stands.

3.  Lift the fuel tank assembly near the position.

4.  Connect connectors at fuel pump.

5.  Lift the fuel pump to its position and secure it with

mounting bolts. Make sure that all hoses and fuel lines
are out of way between the fuel tank and the fuel tank
bracket. Tighten the fuel tank retaining bolts to 36 N

⋅m

(3.7kgf

⋅m).

6E1-272  DRIVEABILITY AND EMISSIONS

6.  Connect fuel supply and return lines.

7.  Connect the fuel filler hose, the air breather hose and

EVAP hose onto fuel tank and secure them with clamps.

8.  Pour fuel into fuel tank.

9.  Install fuel filler cap securely.

10.  Connect the battery negative cable.

THROTTLE BODY (TB)

Removal

1.  Disconnect the negative battery cable.

2.  Drain the cooling system. Refer to Cooling System.

3.  Remove the air intake duct. Refer to Air Intake Duct

Removal Procedure.

4.  Remove the accelerator cable from throttle. Refer to

Accelerator Cable Assembly Removal Procedure.

5.

Disconnect the al connectors from the throttle position
sensor and the idle air control valve solenoid.

6.  Disconnect all vacuum hoses below air horn.

7.  Disconnect coolant lines.

8.  Remove the mounting nuts retaining the throttle body to

the intake manifold.

9.  Remove the throttle body from the intake manifold.