2007 ISUZU KB P190 ECU

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


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 16

4 Release the 3 clips (1) on the passenger side of the
fuel filter holder and slide the fuel filter from the holder
in the direction of the arrow.

NOTE
Cover the quick connectors to prevent any dirt
from entering the fuel system.
Figure 6C – 14
Inspection
1 Replace the fuel filter if fuel leaks from the filter body or if the fuel filter body itself is damaged.
2 Replace the fuel filter if it is clogged with dirt or sediment or the filter shows signs of being contaminated with water or other foreign materials.
Reinstallation
1 Slide the fuel filter into the holder attached to the front of the fuel tank, make sure the three plastic locking
clips secure the filter in place.
NOTE
• Ensure the fuel filter inlet line is facing the
drivers side if the vehicle and the outlet line is
facing the passengers side of the vehicle.
• The direction arrow indicates the direction of
fuel flow.
2 Connect the inlet and outlet fuel line quick connectors to the fuel filter, refer to 4.1 Fuel Lines And Quick
Connect Fittings.
Figure 6C – 15


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 20

8 From behind the fuel filler door (1), unscrew the fuel
filler cap (4) and cover the end of the fuel filler neck
with a suitable material to prevent foreign objects from
entering the fuel tank.
9 Remove the screw (2) securing the fuel filler neck (3) to the fuel filler pocket.
10 Remove the front half of the right-hand rear wheelhouse liner, refer to 10 Cab.

Fuel filler neck attaching screw
torque specification ..............................................5.0 Nm
Figure 6C – 18
11 Unclip the fuel filler door release cable (1) from the retainer on the fuel filler neck (2).
Figure 6C – 19
12 Lower the fuel filler neck and breather hose assembly.
13 Loosen the clamp (2) and disconnect the fuel tank breather hose (3) from the fuel filler neck (1).
Figure 6C – 20

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
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.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 34

Fuel Tank Lines

Figure 6C – 38
Legend
1 Fuel Feed Line
2 Fuel Return Line
3 Fuel Vapour emission port
4 Fuel Pump and Sender Assembly
5 Connector; Fuel Pump and Sender 6 Fuel Lines
7 Retainer Ring (Fuel Pump Lock)
8 “O” Ring Seal
9 Fuel Tank Assembly
10 Fuel Vapour Vent Line
Reinstall

Ensure the plastic fuel line clips are in good
condition before proceeding. If not, replace
the defective clips.
Reinstallation of the stone guard and fuel lines is the reverse of the removal procedure, noting the following:
1 Tighten the Fuel line securing nut to the correct torque specification, refer to Figure 6C – 39.
Fuel line securing nut
torque specification .........................................8 – 12 Nm
2 Tighten the stone guard securing bolts to the correct torque specification. Stone guard securing bolt
torque specification .....................................5.0 – 7.0 Nm

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 35

Fuel Line Routing

Figure 6C – 39
Legend
1 Evaporative Emission Control Canister Purge Line
2 Fuel Feed Line
3 Fuel Line From Fuel Filter 4 Fuel Feed Line To Fuel Filter
5 Evaporative Line To Rollover Valve
6 Evaporative Line To Canister
7 Fuel Line Securing Nut
8 Stone Guard
9 Side Stone Guard

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007