2004 ISUZU TF SERIES fuel pump

ENGINE FUEL (6VE1 3.5L) 6C-9




140R100028
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 a
t
49N (5kgf) it out to make sure that it is not drawn
and is securely locked.




140R100036

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 dus
t
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 affec
t
the fuel injection system.

6C-10 ENGINE FUEL (6VE1 3.5L)
Fuel Pump Relay
General Description
In order to control the fuel pump and sender assembly
(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.

6C-12 ENGINE FUEL (6VE1 3.5L)
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 slowly the fuel filler cap.
NOTE: To prevent spouting out fuel to change the
pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any
dust entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house on rea
r
left side.
6. Remove fasten bolt to the filler neck from the
body.
7. Disconnect the quick connector (8) into the fuel
tube from the fuel pipe and the evapo tube from
evapo joint connector.
NOTE: Cover the quick connector to prevent any dus
t
entering and fuel leaking.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
8. Remove fasten bolt (1) to the tank band and the
tank band (2).
9. Disconnect the pump and sender connector on the
fuel pump and remove the harness from weld clip
on the fuel tank.
10. Lower the fuel tank (6).
NOTE: When the fuel tank is lowered from the vehicle,
don’t scratch each hose and tube by around other pars.


Installation
1. Rise the fuel tank into position.
NOTE: Ensure hoses and tubes do not foul on othe
r
component.
2. Connect the pump and sender connector to the
fuel pump and install harness to into the plastic clip
welded to the top of the fuel tank..
NOTE: The connector must be certainly connected
against stopper.
Ensure tank band anchor mates with guide hole on
frame.
3. Install the tank band to fasten bolt.
Torque: 68 N




m (6.9kg




m/50 lb ft)
NOTE: The anchor of the tank band must be certainly
installed to guide hole on frame.
4. Connect the quick connector from the fuel tube to
the fuel pipe and the evapo tube from evapo join
t
connector.
NOTE: Pull off the left checker into the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
5. Install the filler neck to the body by bolt.
6. Install the inner liner of the wheel house on rea
r
side.
7. Remove lifter to support underneath of the fuel
tank.
8. Put back the vehicle.
9. Tigten the filler cap until at least three clicks are
heard.
10. Connect the battery ground cable.

ENGINE FUEL (6VE1 3.5L) 6C-13
Filler Neck
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck
assembly is restored.

Each joint area of the hose (to restore axial
direction and insertion length of the hose)

Each fasten area of the clamp (to restore axial
direction and position of the clamp)

Each bolt in the clamp (to restore fasten length
of bolt in the clamp)

The band clip (to restore position and fasten
length of the band clip)
NOTE: Cover end of each hose and pipe to prevent any
dust entering.
Installation
1. Align each marking and restore the following point.

Each joint area of the hose (Restore axial
direction and insertion length of the hose)

Each fasten area of the clamp (Restore axial
direction and position of the clamp)

Each bolt in the clamp (Restore fasten length o
f
bolt in the clamp)
Torque: 2.5 N




m (0.25 kg




m / 2 lb ft) … filler neck
side except flat deck model.

The band clip (Restore position and fasten
length of the band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.


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 sende
r
assembly.

6C-16 ENGINE FUEL (6VE1 3.5L)
Special Tools

ILLUSTRATION PART NO.
PART NAME


5–8840–2602–0
(J–39765)
Remover; fuel pump
retainer

6E-8 3.5L ENGINE DRIVEABILITY AND EMISSIONS





(1) Bank 1 Heated Oxygen Sensor (RH)



(1) Bank 2 Heated Oxygen Sensor (LH)





1
(1) Crankshaft Position (CKP) Sensor



(1) Camshaft Position Sensor (CMS)
(2) EGR Valve





(1) Canister



(1) Fuel Tank
(2) Fuel Pump

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-29

No. Connector face No. Connector face
E-78

O2 sensor LH-Front P-1
SilverBattery (+)
E-79


Neutral start switch P-2
SilverRelay & Fuse box
F-2
White
Fuel pump & sensor P-5
SilverBattery (-)
H-4

White Engine ~ Engine room P-8

WhiteACG (L)
H-6
White
Engine room ~ INST P-10
SilverEngine ground
H-7
White
Engine room ~ INST X-2

BlackRelay ; Fuel pump
H-9
Blue
Engine room ~ Chassis X-13

BlackRelay ; ECM MAIN
H-18
White
Engine room ~ INST X-14

BlackRelay ; A/C Compressor
H-22

White
Engine ~ Engine room C X-15
BlackRelay ; Thermo
H-23

White Engine ~ Engine room B X-17
BlackDIODE

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-31

RELAY AND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX

RELAY
NO. Relay name
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; FOG LIGHT
X-6 RELAY; STARTER
X-7 RELAY; COND, FAN
X-8 RELAY;

X-9 RELAY; HAZARD-RH
X-10 RELAY; HAZARD-LH
X-11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; ECM MAIN
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO


FUSE





 
 
 
 


  
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