Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1377

ENGINE FUEL (6VD1 3.2L)

6C–7

NOTE:  After removing pump assembly (4), cover fuel
tank to prevent any dust entering.

Installation

1. Install FPS assembly(4) with retainer (7) and new

seal; fuel pump (9) by J–39765.

2. Install Fuel Tube/Quick Connector (2).

NOTE:  Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.

3. Install fuel tank assembly(8). Refer to “Fuel Tank

Installation”.

Fuel Tube / Quick – Connector Fittings

Precautions

• Do not light a match or create a flame.

• Keep flames away from your work area to prevent

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 similar heat-generating work.

Cautions During Work

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Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was     wiped on
the piping cannot be used.

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.

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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.

Legend

(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube

6C–8

ENGINE FUEL (6VD1 3.2L)

2. For removal of the quick connector, hold the quick

connector in one hand, and pull out the connentor
with the other hand while pressing the square
relieve button of the connector, as illustrated.

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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.

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

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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. 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.

ENGINE FUEL (6VD1 3.2L)

6C–9

Fuel Pump Relay

General Description

In order to control the FPS operation, the FPS relay is
provided. When the starter switch is turned to “ON”
position, the FPS relay operates the FPS for 2 seconds.

When the key 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 FPS to feed fuel.

Fuel Tank

Fuel Tank and Associated Parts

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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. Drain the fuel from the fuel tank, refer to the “Fuel

Pump Flow Test” in this section.

2. Disconnect battery ground cable.

3. Loosen fuel filler cap to reduce the pressure in fuel

tank.

4. Support underneath of the fuel tank assembly (1)

with a lifter.

5. Disconnect fuel feed hose (7) and fuel return hose

(8) near the fuel filter.

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

Legend

(1) Fuel Tank Assembly
(2) Fuel Tank Fixing Bolt (QTY: 5)
(3) Fuel Tank Fixing Nut (QTY: 1)
(4) Separator Fixing Bolt (QTY: 2)
(5) Fuel Filler Hose

(6) Fuel Vent Hose
(7) Fuel Feed Hose
(8) Fuel Return Hose
(9) Tank Pressure Sensor Connector

(10) Fuel Feed Pump Connector

6C–10

ENGINE FUEL (6VD1 3.2L)

6. Disconnect fuel filler hose (5) and fuel vent hose (6)

at the fuel filler neck.

NOTE:  Cover fuel hoses to prevent any dust entering.

7. Remove two bolts (4) and remove separator.

8. Remove the five fuel tank assembly fixing bolts (2)

and one nut (3).

9. Lower the tank and disconnect the wiring

connectors (9, 10).

Installation

1. Raise the fuel tank assembly (1) and connect the

wiring connectors (9, 10).

2. Install fuel tank assembly along with protectors and

tighten the five fixing bolts (2) and one nut (3) to the
specified torque.

Torque: 68 N·m (50 lb ft)

3. Install the separator and tighten two bolts (4).

Torque: 10 N·m  (95 lb in)

4. Connect fuel filler hose (5) and fuel vent hose and

clip them firmly.

5. Connect fuel feed hose (7) and fuel return hose (8),

and clip them firmly.

6. Tighten fuel filler cap until at least three clicks are

heard.

7. Connect battery ground cable.

Fuel Gauge Unit

Removal and Installation

Refer to “Fuel Pump” in this section for removal and

installation of the Fuel Gauge Unit, since the fuel
gauge unit is linked to the fuel pump and sender
assembly. 

Fuel Filler Cap

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.

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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.

Legend

(1) Vacuum Valve
(2) Pressure Valve
(3) Seal Ring