2007 ISUZU KB P190 Fuel line

Fuel System – V6 Page 6C – 1

6C
Fuel System – V6
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to 1.1 WARNING,
CAUTION and NOTES for correct workshop practices with regard to safety and/or property damage.
1 General Information ............................................................................................................ ...................3
Description ............................................................................................................................................................. 3
Service Precautions............................................................................................................................................... 3
1.1 WARNING, CAUTION and NOTES ..................................................................................................... ................... 4
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 4
WARNING defined ............................................................................................................................................. 4
CAUTION defined .............................................................................................................................................. 4
NOTE defined..................................................................................................................................................... 4
2 System Components .............................................................................................................. ................5
Fuel System ............................................................................................................................................................ 5
Description ......................................................................................................................................................... 5
Fuel Pump............................................................................................................................................................... 6
Single Turbine Fuel Pump ....................................................................................................... ........................... 6
Fuel Flow ................................................................................................................................................................ 7
3 System Checks .......................................................................................................................................8
3.1 Fuel Pump Flow Test ............................................................................................................................................. 8
3.2 Fuel Pressure Test ................................................................................................................................................. 8
Gauge Installation .................................................................................................................................................. 8
Test ......................................................................................................................................................................... 9
Removal .................................................................................................................................................................. 9
3.3 Fuel Leak Test ...................................................................................................................................................... 10
3.4 Fuel System Depressurisation................................................................................................... ......................... 11
Repressurise ........................................................................................................................................................ 12
4 Service Operations ...............................................................................................................................13
4.1 Fuel Lines And Quick Connect Fittings .......................................................................................... ................... 13
Description ........................................................................................................................................................... 13
Leak Test and Inspection .................................................................................................................................... 13
Removal ................................................................................................................................................................ 14
Reinstall ................................................................................................................................................................ 15
4.2 Fuel Filter.............................................................................................................................................................. 15
Removal ........................................................................................................................ ........................................ 15
Inspection ............................................................................................................................................................. 16
Reinstallation ................................................................................................................. ...................................... 16
4.3 Fuel Tank and Pump Assembly .................................................................................................... ...................... 17
4.4 Fuel Tank Assembly ............................................................................................................................................ 18
Remove ................................................................................................................................................................. 19
Reinstall ................................................................................................................................................................ 22
4.5 Modular Fuel Pump and Sender Assembly .......................................................................................... ............. 23
Remove ................................................................................................................................................................. 23
Fuel Level Sender Assembly ..................................................................................................... ......................... 26
Test .................................................................................................................................................................. 26
Reinstall ................................................................................................................................................................ 26

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 2

4.6 Evaporative Emission Control Canister............................................................................................................. 27
Remove ................................................................................................................................................................. 27
Service Check .................................................................................................................. .................................... 28
Reinstall ................................................................................................................................................................ 29
4.7 Fuel Tank Siphon Procedure ..................................................................................................... ......................... 30
4.8 Fuel Filler Cap ...................................................................................................................................................... 32
Remove ................................................................................................................................................................. 32
Inspection ......................................................................................................................................................... 32
Reinstall ................................................................................................................................................................ 32
4.9 Fuel Lines ..................................................................................................................... ........................................ 33
Remove ................................................................................................................................................................. 33
Fuel Tank Lines ................................................................................................................ .................................... 34
Reinstall ................................................................................................................................................................ 34
Fuel Line Routing.............................................................................................................. ................................... 35
Bell Housing Fuel Lines ........................................................................................................ .............................. 36
Engine Bay Fuel Lines......................................................................................................................................... 36
4.10 Rollover Valve ...................................................................................................................................................... 37
5 Specifications .......................................................................................................................................38
6 Torque Wrench Specifications................................................................................................... .........39
7 Special Tools ........................................................................................................................................40



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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 3

1 General Information
Description
Fuel is injected into the engine by separate fuel injectors that are mounted in the intake manifold (common chamber).
Fuel is supplied to the injectors under pressure from the fuel tank through the fuel lines and the fuel rail, which is
attached to the top of the common chamber.

A fuel pressure control valve is installed on the fuel rail to maintain fuel line pressure across the injectors under all
operating conditions. Fuel pressure is maintained by controlling the amount of fuel that is supplied from the fuel tank,
based on the demand of the engine via the engine control module (ECM).

Two interchangeable “O” rings are used on the fuel injector and must be replaced when the injectors are removed.
The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft revolution.
The ECM controls the injector on time so that the correct amount of fuel is metered depending on driving conditions.
The V6 engine is designed to use only unleaded petrol.

Unleaded petrol must be used for correct emission control system operation and its use will also minimize spark plug
fouling and extend engine oil life.

Using leaded petrol can damage the emission control system and could void the vehicle warranty. All vehicles are
equipped with an Evaporative Emission Control System. The purpose of the system is to minimize the escape of fuel
vapours into the atmosphere.
Service Precautions
• Use extreme care when working on the fuel system and follow all safety precautions.
• W hen working on the fuel system, disconnect the battery ground cable except for tests where battery voltage is
required.
• Always keep a dry chemical (class B) fire extinguisher near the work area.
• Relace all fuel lines and fittings with the same type of line and fitting as those removed.
• Clean and inspect “O” rings carefully and replace if required.
• Always depressurize the fuel lines before servicing any fuel system components.
• Do not attempt any repairs on the fuel system until, all warnings and instructions, relating to that repair have been
read and ensure all notices and cautions are adhered to.
• Do not allow any naked frames or sparks near the work area when working on the fuel system.
• If draining of the fuel system is required, this should be done in a well ventilated area.
• Protect the fuel lines and associated parts from thermal damage, spattering when welding.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 5

2 System Components
Fuel System

Figure 6C – 1
Legend
1 Fuel Tank
2 Fuel Pump and Sender Assembly
3 Fuel Filter 4 Fuel Feed Line
5 Evaporative Control Valve
6 Fuel Pressure Test Point 7 Evaporative Return Line
8 Evaporative Canister

Description
The modular fuel pump and sender assembly maintains an optimum fuel level in the reservoir. This ensures a continuous fuel flow under all fuel level conditions and vehicle attitudes. The modular fuel pump and sender
assembly also provides an accurate means of measuring the fuel level within the fuel tank.

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Fuel System – V6 Page 6C – 7

Fuel Flow
Fuel (A) is drawn into the modular fuel pump and sender
assembly reservoir from the fuel tank, through the primary
umbrella valve (5) and into the fuel pump impeller, via the
internal strainer (4) at the fuel pump (1) inlet. At the impeller,
vapour (C) is separated from the fuel. The vapour is ejected
from the fuel pump into the reservoir via a port next to the
fuel pump inlet.
High-pressure fuel then flows through the end cap, the lower
connector and the flexible line. From the flexible line, fuel
exits the modular fuel pump and sender assembly through
the fuel feed port and flows on to the externally-mounted
fuel filter and the engine.
A fuel pressure regulator is located in the modular fuel pump
and sender assembly; fuel not used by the engine (B) is
returned to the modular fuel pump and sender assembly via
the fuel return line and the fuel return port in the modular
fuel pump and sender assembly cover. The return fuel
enters the jet pump standpipe (3) of the reservoir via the
return fuel tube.
Vehicle fuel line pressure is maintained by a pressure
regulator (2) located within the modular fuel pump and
sender assembly.
W hen the engine is switched off, the reservoir remains full of
fuel, due to the action of the primary umbrella valve. At high
fuel levels, fuel tank overflow enters the reservoir over the
top of the reservoir. Fuel level in the reservoir is also
maintained by returned engine fuel.
Electrical power is supplied to the fuel pump by a connector
secured to the modular fuel pump and sender assembly
cover. An internal harness (not shown) assembly completes
the connection to the pump.
Figure 6C – 3


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Fuel System – V6 Page 6C – 8

3 System Checks
3.1 Fuel Pump Flow Test
If a reduction of the fuel supply is suspected, perform the following checks.
1 Ensure there is sufficient fuel in the tank.
2 W ith the engine running, check the fuel lines from the fuel tank to the injectors for evidence of leakage.
Retighten, if the lines or the connections are loose.
Also, check the fuel lines for restrictions such as
squashed or clogged fuel line.
3 Depressurize the fuel system, refer to 3.4 Fuel System Depressurisation.
4 Disconnect the fuel line at the fuel rail.
5 Connect a hose from the fuel line and place the open end into a clean container.
6 Connect the fuel pump relay terminals (2) with a jumper wire (1) as shown, then turn the ignition to the
ON position to operate the fuel pump, then check the
fuel pump flow rate.

Do not generate any sparks when connecting
the jumper wire.
Fuel delivery test time ....................................... 15.0 Sec
Fuel delivery rate .....................................0.38 Litres Min
NOTE
If the fuel flow rate is below the minimum value,
conduct a fuel pressure test, refer to 3.2
Fuel Pressure Test.
Figure 6C – 4

3.2 Fuel Pressure Test

To reduce the risk of fire or personal injury,
depressurise the fuel system before servicing
any fuel system components, refer to 3.4
Fuel System Depressurisation.
Gauge Installation
1 Turn the ignition switch off.
2 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.

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Fuel System – V6 Page 6C – 10


After relieving the fuel system pressure, a
small amount of fuel may be released when
servicing the fuel lines or connections. Cover
the fittings with a shop towel before
disconnecting. This catches any leaking fuel.
Place the soiled towel in an approved
container when disconnection is completed.
3 W rap a shop towel around the fuel pressure test point to absorb any fuel spillage.
4 Remove the fuel pressure gauge and drain any fuel remaining in the fuel pressure gauge into an approved fuel container.
5 Remove the soiled shop towel and place in an approved container.
6 Repressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
7 Road-test the vehicle and check for correct operation.
3.3 Fuel Leak Test

After installing any fuel system component
and before starting the engine, check the fuel
system for leaks.
NOTE
For the fuel injector leak-down test (for vehicles
fitted with a V6 engine), refer to 6C1-3 Engine
Management – V6 – Service Operations.
1 Turn the ignition switch on for two seconds.
2 Turn the ignition switch off for 10 seconds.
3 Turn the ignition switch on.
4 Check for fuel leaks, particularly at points marked z (that is, quick-connect fittings, fuel rails, fuel injectors,
Schrader valve and evaporative emission control canister purge solenoid, refer to Figure 6C – 6.

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Fuel System – V6 Page 6C – 11


Figure 6C – 6
5 Replace any faulty components and repeat step 2 to step 5 inclusive.
6 Replace all engine components removed to perform the fuel leak test, refer to 6C1-3 Engine Management – V6 – Service Operations.
3.4 Fuel System Depressurisation

To reduce the risk of fire or personal injury,
depressurise the fuel system before servicing
any fuel system components.
1 Turn the ignition switch off.
2 Remove the fuel pump fuse and fuel pump relay, refer to 8A Electrical Body and Chassis.
3 Loosen the fuel filler cap to relieve the fuel tank vapour pressure.
4 W ith the throttle closed, crank the engine.
NOTE
The engine may start and operate until the fuel
remaining in the fuel delivery system depletes.
5 W hen the engine stops, crank the engine for another 10 seconds to ensure the fuel feed line pressure has been fully relieved.
6 Clean the area around the fuel pressure test point.

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ISUZU KB P190 2007