Isuzu KB P190. Manual - part 806

Fuel System – V6

Page 6C – 22

Reinstall

Reinstallation of the fuel tank is the reverse of the removal procedure, noting the following:

Lift the fuel tank into position reinserting the fuel tank inlet and breather hoses into the body opening. Raise the fuel
tank into place and rest the front of the tank on the crossmember.

Replace the fuel pump electrical connector, be sure to engage the locking tab.

Fit the fuel tank mounting straps in the following order, refer to Figure 6C – 17,

Loosely reattach the rear fuel tank mounting strap and bolt (8 & 9), refer to Figure 6C – 17.

Loosely attach the front mounting strap and bolt (1 & 2), refer to Figure 6C – 17.

Ensure that the fuel tank is located in the correct position then,

Tighten the rear mounting strap bolt (8), Figure 6C – 17.

Tighten the front mounting strap bolt (1), Figure 6C – 17.

Tighten all fuel tank mounting strap bolts to the correct torque specification.

Fuel tank mounting strap bolts
torque specification ............................................68.0 Nm

Install the fuel filter with the flow arrow on its
body pointing in the same direction as the
fuel flow to the front of the vehicle.

Install the disconnected quick-connect fittings to the fuel supply line at the front of the fuel tank and the evaporative
line quick-connect fitting at the rear of the fuel tank. Refer to 4.1 Fuel Lines And Quick Connect Fittings, for the
correct component routeing.

Lower the vehicle to a comfortable working height and reinstall the clamp (1) to the fuel filler neck and reconnect
the rubber fuel tank inlet hose (2) and tighten the clamp, refer to Figure 6C – 21.

Reinstall the fuel tank breather hose (3) to the fuel filler neck (1) and tighten the clamp (2), refer to Figure 6C – 20.

Clip the fuel filler door release cable (1) to the retainer on the fuel filler neck (2), refer to Figure 6C – 19.

Locate the fuel filler neck (3) to the filler pocket and attach with the securing screw (2), remove the cover material
from the fuel filler neck inlet and refit the fuel filler cap (4), refer to Figure 6C – 18.

Reinstall the front half of the right-hand rear wheelhouse liner, refer to 10 Cab.

Before starting the vehicle, perform a fuel system leak test, refer to 3.3

Fuel Leak Test.

Fuel System – V6

Page 6C – 23

4.5

Modular Fuel Pump and Sender
Assembly

N O T E

If the modular fuel pump and sender assembly
develops a fault it must be replaced as a
complete unit. The only serviced parts are the
retainer locking ring and the O-ring seal.

Remove

• A depressurised fuel system contains fuel

in the fuel filter and fuel lines that can be
spilled during service operations.

• Fuel vapour remains in the fuel tank even

when completely empty. Seal all openings
in the fuel tank using suitable material or a
plastic plug. Ensure no naked flames or
other ignition sources are nearby. Ensure
all cellular phones (and transmission
devices that may cause any metal objects
to become unintentional receiving
antennas) are switched off.

• Place a dry chemical (Class

B) fire

extinguisher nearby before performing any
on-vehicle service procedures. Failure to
follow these precautions may result in
personal injury.

• Wear safety glasses when using

compressed air. Do not blow compressed
air directly onto any body part.

Remove the fuel pump relay, refer to 8A Engine Body and Chassis.

Remove the fuel tank assembly from the vehicle, refer to 4.4

Fuel Tank.

Before proceeding, clean all traces of dirt and
other foreign material from the top of the fuel
tank, near the modular fuel pump and sender
assembly.

Use compressed air to ensure all dirt and foreign materials are removed from all fuel connections before
disconnecting the parts.

Fuel can spill from the disconnected modular
fuel pump and sender assembly.

Fuel System – V6

Page 6C – 24

Tag the fuel feed line connecting the fuel feed port (1)
on the modular fuel pump and sender assembly cover.

Tag the fuel return port (2) on the modular fuel pump
and sender assembly cover.

Tag the evaporative line on the modular fuel pump and
sender assembly cover (3).

Figure 6C – 23

Disengage the fuel feed line quick-connect fitting (1).

Disengage the fuel return line quick-connect fitting (2).

Disengage the evaporative line quick-connect fitting
(3).

Refer to 4.1

Fuel Lines And Quick Connect Fittings.

Figure 6C – 24

• Ensure tool No. AU469 is seated firmly and

positively in the modular fuel pump and
sender assembly cover retainer lock ring
while removing the modular fuel pump and
sender assembly.

• Assistance will be required to hold the

tank in position during this procedure; if
not held adequately, you may slip and
damage the modular fuel pump and sender
assembly.

Fuel System – V6

Page 6C – 25

Using tool No. AU469 (3) and a half-inch breaker
bar (1), remove the modular fuel pump and sender
assembly cover retainer lock ring (2) by turning it
anticlockwise.

Remove the modular fuel pump and sender assembly
cover retainer lock ring.

Figure 6C – 25

The reservoir will be full of fuel. When the
modular fuel pump and sender assembly is
removed from the fuel tank, pour any
remaining fuel in the reservoir into a suitable
container. Do not drain or store fuel into an
open container, due to the possibility of fire
or explosion.

Place the modular fuel pump and sender assembly
cover retainer lock ring (1) in a safe location away
from the immediate worksite.

Carefully lift the modular fuel pump and sender
assembly from the fuel tank, taking care not to:

•

damage the fuel level sender float and arm (2),
or

•

spill any fuel remaining in the reservoir

N O T E

The fuel sender float arm is not serviced
separately. If damaged, the modular fuel pump
and sender assembly is replaced as a complete
assembly.

Remove and discard the O-ring (3).

Figure 6C – 26

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