2007 ISUZU KB P190 Fuel line

Fuel System – V6 Page 6C – 21

14 Remove the clamp (1) from the fuel filler neck and
disconnect from the rubber fuel tank inlet hose (2),
place the removed filler neck (3) in a safe location.
15 Raise the vehicle, preferably on a hoist, refer to 0A General Information.
Figure 6C – 21

Wear safety glasses when using compressed
air. Do not blow compressed air onto any
body part.
16 Use compressed air to ensure that all dirt and foreign materials are removed from all fuel connections before
the parts are disconnected.
17 Disconnect the quick-connect fitting from the fuel supply line at the front of the fuel tank (1) and the
evaporative line quick-connect fitting at the rear of the
fuel tank (2), refer to 4.1 Fuel Lines And Quick
Connect Fittings.
Figure 6C – 22

18 Remove the bolt securing the front fuel tank strap (1) to the crossmember and remove the strap (2), refer to Figure 6C – 17.

Support the fuel tank with stands or have an
assistant on hand to help in the fuel tank
removal.
19 Remove the bolt from the rear fuel tank strap (8) then remove the strap (9) refer to Figure 6C – 17.
20 Lower the rear of the fuel tank enough to allow access to the fuel pump electrical connector, release the connector clip and remove the connector from the socket.
21 Lower the fuel tank from the vehicle, ensuring the fuel tank inlet and breather hoses do not foul on any obstruction during the process.
22 Remove the fuel tank from the vehicle.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 22

Reinstall
Reinstallation of the fuel tank is the reverse of the removal procedure, noting the following:
1 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.
2 Replace the fuel pump electrical connector, be sure to engage the locking tab.
3 Fit the fuel tank mounting straps in the following order, refer to Figure 6C – 17, a Loosely reattach the rear fuel tank mounting strap and bolt (8 & 9), refer to Figure 6C – 17.
b Loosely attach the front mounting strap and bolt (1 & 2), refer to Figure 6C – 17.
c Ensure that the fuel tank is located in the correct position then,
d Tighten the rear mounting strap bolt (8), Figure 6C – 17.
e Tighten the front mounting strap bolt (1), Figure 6C – 17.
4 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.
5 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.
6 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.
7 Reinstall the fuel tank breather hose (3) to the fuel filler neck (1) and tighten the clamp (2), refer to Figure 6C – 20.
8 Clip the fuel filler door release cable (1) to the retainer on the fuel filler neck (2), refer to Figure 6C – 19.
9 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.
10 Reinstall the front half of the right-hand rear wheelhouse liner, refer to 10 Cab.
11 Before starting the vehicle, perform a fuel system leak test, refer to 3.3 Fuel Leak Test.



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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 23

4.5 Modular Fuel Pump and Sender
Assembly
NOTE
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.
1 Remove the fuel pump relay, refer to 8A Engine Body and Chassis.
2 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.
3 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.

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Fuel System – V6 Page 6C – 24

4 Tag the fuel feed line connecting the fuel feed port (1)
on the modular fuel pump and sender assembly cover.
5 Tag the fuel return port (2) on the modular fuel pump and sender assembly cover.
6 Tag the evaporative line on the modular fuel pump and sender assembly cover (3).
Figure 6C – 23
7 Disengage the fuel feed line quick-connect fitting (1).
8 Disengage the fuel return line quick-connect fitting (2).
9 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.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 27

4.6 Evaporative Emission Control Canister
Remove
1 Raise the vehicle on a hoist to give access to the evaporative emission control canister, located above the spare
wheel , refer to 0A General Information.
2 Disconnect the evaporative emission control canister purge line (3) by using the following procedure:
a Grasp both sides of the quick-connect fitting. Twist the connector 1/4 turn in each direction in
order to loosen any dirt within the quick-connect
fitting.

Wear safety glasses when using compressed
air. Do not blow compressed air onto any
body part.
b Using compressed air, blow any dirt out of the quick-connect fitting.
c Grasp the quick-connect fitting and push it towards the canister.
d Squeeze the quick-connect fitting to release the retaining tabs, then pull back on the connector to
remove the canister purge line from the canister.
Figure 6C – 28
3 Disconnect the fuel tank vent line (4) by using the following procedure:
a Grasp both sides of the quick-connect fitting. Twist the connector 1/4 turn in each direction in
order to loosen any dirt within the quick-connect
fitting.

Wear safety glasses when using compressed
air. Do not blow compressed air onto any
body part.
b Using compressed air, blow any dirt out of the quick connect fitting.
c Grasp the quick-connect fitting and push it towards the canister.
d Squeeze the quick-connect fitting to release the retaining tabs, then pull back on the connector to
remove the tank vent line from the canister.
Figure 6C – 29

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Fuel System – V6 Page 6C – 28

4 Remove the canister vent line (2) from the canister (1)
by twisting and pulling it off.
Refer to 4.1 Fuel Lines And Quick Connect Fittings for further information.
Figure 6C – 30
5 Remove the canister retaining nut (2).
6 Remove the canister from the retaining stud and then slide the canister (3) out of the retaining bracket (1).
Figure 6C – 31
Service Check
1 Remove the canister.
2 Shake the canister. There should be no audible sound of carbon movement.
3 Using low pressure compressed air (20–35 kPa), blow into the tank vent port (3). Check that air flows freely
from the canister vent port (1). Block the canister vent
port (1); air should flow from the canister purge
port (2).
4 If airflow through the canister vent port (1) is limited, clean the atmospheric filter by blocking off the fuel
tank vent port (3) and blow compressed air at
approximately 300 kPa through the canister purge
port (2).
5 Check airflow through the filter as in step 3. If airflow through the canister vent port (1) is still limited, replace
the canister.
Figure 6C – 32

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Fuel System – V6 Page 6C – 29

6 Block the canister vent port (1) and the canister purge port (2). Apply low-pressure compressed air
(20–35 kPa) to the tank vent port (3). If any air leaks from the canister (that is, around the ports or seams), replace
the canister.
NOTE
In dusty areas, an alternative is to block the
canister purge port (2). Blow air through the
canister vent (1) port and check that air is
expelled through the tank vent port (3).
Reinstall
Reinstallation of the evaporative emission control canister is the reverse of the removal procedure.
1 Reinstall the canister into the retainer (1) and over the retaining stud.
2 Reinstall the canister retaining nut (2), then hand- tighten.
3 Ensure the canister is located correctly and tighten the canister retaining nut (2) to the specified torque.


Evaporative emission control canister
retaining nut
torque specification .....................................2.0 – 5.0 Nm

Figure 6C – 33
4 Reinstall the canister vent line (2).
5 Align the canister purge line quick-connect (3) with the canister purge line port. Push the quick-connect firmly
onto the port.
6 Align the fuel tank vent line quick-connect (4) with the fuel tank vent port. Push the quick-connect firmly onto
the port.
7 After installation, pull on each quick-connect to ensure the connections are secure and locked in position.
Figure 6C – 34


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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 30

4.7 Fuel Tank Siphon Procedure

• Fuel vapour remains in the modular fuel
pump and sender assembly and fuel lines
that can be spilled during service
operations. 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.
For an exploded view of fuel tank components, refer Figure 6C – 17.
1 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
2 Reinstall the fuel pump relay, refer to 8A Electrical Body and Chassis.

Disconnecting the battery affects certain
vehicle electronic systems. 1.1 WARNING,
CAUTION and NOTES.
3 Disconnect the negative battery terminal.
4 Remove the fuel filler cap.
NOTE
Lubricate the fuel siphon hose with J36850
TransJel Transmission Assembly Lubricant or
equivalent to aid hose insertion. Use only an
approved lubricant.
5 Install J44284–2 flapper door holder (2) into the fuel filler neck to hold the door open.

Do not siphon, drain or store fuel into an
open container, due to the possibility of fire
or explosion, or contamination. Always use
and approved fuel storage container.
6 Insert the J45004–1 fuel tank siphon hose (1) into the fuel tank filler neck and gradually twist it until the tip of
the hose meets the fuel tank check valve (3) and
continues to the bottom of the fuel tank.
7 Use a hand-operated or air-operated pump device to siphon as much fuel through the fuel fill pipe as
possible.

Figure 6C – 35

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