2007 ISUZU KB P190 Workshop Repair Manual

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Page 3201 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–66

6 Torque Wrench Specifications
N.m
Coolant Outlet housing to Engine Outlet Attaching Bolts............................... 10
Coolant Pump to Front

Page 3202 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–67

7 Special Tools
Tool number Illustration Description Classification
AU505
Coolant Tester
Used for testing the coolant
concentration level.
Previ

Page 3203 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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 fo

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

Page 3204 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Fuel System – V6 Page 6C – 2

4.6 Evaporative Emission Control Canister............................................................................................................. 27
Remove ..

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

Page 3205 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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

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

Page 3206 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Fuel System – V6 Page 6C – 4

1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death

Fuel System – V6 Page 6C – 4

1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
GM HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these
instructions.
Definition of WARNING, CAUTION and NOTE Statements
Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. GM HOLDEN LTD is dedicated to the presentation of service information that helps the technician to
diagnose and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard
to the technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
• Present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.

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ISUZU KB P190 2007

Page 3207 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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 Contr

Page 3208 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Fuel System – V6 Page 6C – 6

Fuel Pump
Single Turbine Fuel Pump
The fuel pump is an integral part of the Fuel Pump and Sender Assembly, refer to Figure 6C – 3.
Figure 6C– 2 details t

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