SECTION 6C - ENGINE FUEL (X22SE 2.2L)

Service Precaution

General Description

Fuel Metering

Fuel Filter

Fuel Filter and Associated Parts

Removal

Inspection

Installation

Inspection

In–Tank Fuel Filter

Fuel Pump Flow Test

Fuel Pump

Fuel Pump and Associated Parts

Removal

Installation

Fuel Tube / Quick – Connector Fittings

Precautions

Cautions During Work

Removal

Reuse of Quick–Connector

Assembling Advice

Fuel Pump Relay

General Description

Fuel Tank

Fuel Tank and Associated Parts

Removal

Installation

Fuel Gage Unit

Removal and Installation

Fuel Filler Cap

General Description

Inspection

Main Data and Specifications

Special Tool

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN

POSSIBLE AIR BAG DEPLOYMENT, PERSONAL

INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM

REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

ISUZU will call out those fasteners that require a

replacement after removal. ISUZU will also call out

the fasteners that require thread lockers or thread

sealant. UNLESS OTHERWISE SPECIFIED, do not

use supplemental coatings (Paints, greases, or

other corrosion inhibitors) on threaded fasteners or

fastener joint interfaces. Generally, such coatings

adversely affect the fastener torque and the joint

clamping f or ce, and may dama ge the fastener . Wh en

you install fasteners, use the correct tightening

sequence and specifications. Following these

instructions can help you avoid damage to parts

and systems.

General Description

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(1) Fuel Filte r Cap

(2) Fuel Tank

(3) Rollover Valve

(4) Fuel Pump and Sender Assembly

(5) Fuel Filter

(6) Fuel Rail

(7) Intake Manifold

(8) Fue l Pre ssur e Cont ro l Valve

(9) Throttle Valve

(10) Canister

(11) Evapo Pipe

When working on the fuel system, there are several

things to k eep in mind:

• Any time the fuel system is being worked on,

disconnect the negative battery cable except for

those tests where battery voltage is required.

• Always keep a dry chemical (Class B) fire

extinguisher near the work area.

• Replace all pipes with the same pipe and fittings that

were removed.

• Clean and inspect “O" rings. Replace if required.

• Always relieve the line pressure before servicing any

fuel sys tem com pon ent s.

• Do not attempt repairs on the fuel system until you

have read the instructions and checked the pictures

relating to that repair.

• Adhere to all Notices and Cautions.

All gasoline engines are designed to use only unleaded

gasoline. Unleaded gasoline must be used for proper

emission control system operation.

Its use will also minimize spark plug fouling and extend

engine oil life. Using leaded gasoline can damage the

emissi on con t ro l system and cou ld resu lt in los s of

emission warranty coverage.

All cars are equipped with an Evaporative Emission

Control System. The purpose of the system is to

minimize the escape of fuel v apors to the atmosphere.

Fuel Metering

The Powertrain Control Module (PCM) is in complete

control of this fuel delivery system during normal driving

conditions.

The intake manifold function, like that of a diesel, is

used only to let air into the engine. The fuel is injected

by separate injectors that are mounted over the intake

manifold.

The Manifold Absolute Pressure (MAP) sensor

measures the changes in the intake manifold pressure

which result from engine load and speed changes,

which the MAP sensor converts to a voltage output.

This sensor generates the voltage to change

corresponding to the flow of the air drawn into the

engine.

The changing voltage is transformed into an electric

signal and provided to the PCM.

With receipt of the signals sent from the MAP sensor,

Intake Air Temperature sensor and others, the PCM

determines an appropriate fuel injection pulse width

feeding such information to the fuel injector valves to

effe ct an appropriate air/fuel ratio.

The Multiport Fuel Injection system utilizes an injection

system where the injectors turn on at every crankshaft

revolution. The PCM controls the injector on time so

that the correct amount of fuel is metered depending on

driving conditions.

Two interchangeable “O" rings are used on the injector

that must be replaced when the injectors are remov ed.

The fuel rail is attached to the top of the intake manifold

and supplies fuel to all the injectors.

Fuel is recirculated through the rail continually while the

engine is running. This removes air and v apors from the

fuel as well as keeping the fuel cool during hot weather

operation.

The fuel pressure control valve that is mounted on the

fuel rail maintains a pressure differential across the

injectors under all operating conditions. It is

accomplished by controlling the amount of fuel that is

recirculated back to the fuel tank based on engine

demand.

See Section “Driveability and Emission" for more

information and diagnosis.

Fuel Filter

Fuel Filter and Associated Parts

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Removal

CAUTION: When repair to the fuel system has been

completed, start engine and check the fuel system

for loose connections or leakage. For the fuel

system diagnosis, see Section “Driveability and

Emission".

1. Disco nne ct batte ry ground cable.

2. Remove fuel filler cap.

3. Disconnect fuel hoses(1) from fuel filter on both

engine si de and fuel tank si de.

4. Fuel filter fixing bolt.

• Remove the fuel filter fixing bolt on fuel filter

holder(3).

5. Remove fuel filter(2).

Inspection

1. Replace the fuel filter if the fuel leaks from fuel filter

body or if the fuel filter body itself is damaged.

2. Replace the filter if it is clogged with dirt or

sediment.

3. Check the drain and if it is clogged with dust, clean it

out with air.

Installation

1. Install the fuel filter in the proper direction.

2. Install fuel filter holder fixing bolt.

3. Connect fuel hoses on engine side and fuel tank

side.

4. Install fuel filler cap

5. Connect the battery ground cable.

(1) Fuel Hose

(2) Fuel Filter (3) Fuel Filter Holder

(4) Fuel Hose

Inspection

After installation, start engine and check for fuel leak

age.

In–Tank Fuel Filter

The filter is located on the lower end of the fuel pickup

tube in the fuel tank. It prevents dirt from entering the

fuel pipe and also stops water unless the filter is

completely submerged in the water. It is a self cleaning

type, not requiring scheduled maintenance. Excess

water and sediment in the tank restricts fuel supply to

the engine, resulting in engine stop. In such a case, the

tank must be cleaned throughly.

Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the

following checks.

1.Make sure that there is fuel in the tank.

2.With the engine running, check the fuel feed pipe

and hose from fuel tank to injector for evidence of

leakage. Retighten, if pipe or hose connection is

loose. Also, check pipes and hoses for squashing or

clogging.

3.Insert the hose from fuel feed pipe into a clean

container, and check for fuel pump flow rate.

4.Connect the pump relay terminals with a jumper

wire(1) as shown and start the fuel pump to

measure delivery.

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CAUTION: Never generate sparks when connecting

a jumper wire.

If the measure value is out of standard, conduct the

pressure test.

Pressure test

F or the pressure test to the fuel system, see Section 6E

“Fuel Control System".

Delivery Delivery

15 seconds 0.38 liters minimum

Fuel Pump

Fuel Pump and Associated Parts

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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 fuel filler cap.

3.Support underneath of the fuel tank assembly (13)

with a lifter.

4.Remove fuel tank assembly (13). Refer to “Fuel

Tank Removal" in this section.

5. Remove Fuel Tube/Quick Connector (2).

NOTE: Handling of the fuel tube sure to refer “Fuel

Tube/Quick Connector Fittings" in this section.

(1) Fuel Feed Port

(2) Fuel Tube/Quick Connector

(3) Fuel Return Port

(4) Fuel Pump and Sender Assembly

(5) Connector; Fuel Feed Pump

(6) Connector; Fuel Level Sensor

(7) Fuel pump lock

(8) Hose; Evaporative Fuel

(9) Hose; Air Breather

(10) Hose; Fuel Filler

(11) Fuel Return Hose

(12) Fuel Feed Hose

(13) Fuel Tank Assembly

6.Remove fuel pump and sender (FPAS) assembly(4)

using 5–8840–2602–0.

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NOTE:

•After removing pump assembly (4), cover fuel tank to

prevent any dust entering.

Installation

1.Install FPAS assembly(4) using 5–8840–2602–0.

2.Install Fuel Tube/Quick Connector (2).

NOTE: Handling of the fuel tube sure to refer “Fuel

Tube/Quick Connector Fittings" in this section.

3.Install fuel tank assembly(11). Refer to “Fuel Tank

Installation".

4. Fill the tank with fuel and tighten fuel filler cap.

5. Connect battery ground cable.

Fuel Tube / Quick – Connector Fittings

Precautions

• Li ghting of Fires Proh ib ite d.

• Keep flames away from your work area to prev ent the

inflammable from catching fire.

• Disconnect the battery negative cable to prevent

shorting during work.

• When welding or conducting other heat-generating

work on other parts, be sure to provide pretreatment

to protect the piping system from thermal damage or

spattering.

Cautions During Work

Do not expose the assembly to battery electrolyte or do

not wipe the assembly with a cloth used to wipe off spilt

battery electorolyte.

The piping wet with battery electrolyte cannot be used.

Be careful not to give a bending or twisting force to the

piping during the work. If deformed, replace with a new

piping.

Removal

1. Open the fuel cap to relieve the fuel pressure in the

tank.

If the fuel quick-connect fittings are dusty, clean with

an air blower, etc. and then remove it.

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As some pressure may remain in the piping, cover

the connector with a cloth, etc. to prevent the

splashing of fuel in the first disconnection of the

piping.

2. For removal of the delivery pipe (feeding fuel to the

engine), hold the connector in one hand, and hold

the retainer tab with the other hand and pull out the

connector, as illustrated. The pipe can be removed

with the retainer attached.

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3. For removal of the return pipe (returnig fuel to the

tank), hold the pipe in one hand, and pull out the

connentor with the other hand while pressing the

square relieve button of the retainer, as illustrated.

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This work should be done by hands. Do not use any

tools. Should the pipe can hardly be removed from the

connector , use a lubricant (light oil) and/or push and pull

the connector longitudinally until the pipe is removed.

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When reusing the delivery pipe retainer, reuse

without removing the retainer from the pipe. If the

retainer is damaged or deformed, however, replace

with a new retainer.

Cover the connectors removed with a plastic bag,

etc. to prevent the entry of dust or rain water.

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Reuse of Quick–Connector

• Replace the pipe and connector if scratch, dent or

crac k is found.

• Remove mud and dust from the pipe and make sure

that the end including spool is free of defects , such as

scratch, rust, and dent, which may cause poor

sealability. If defective, replace with a new pipe.

• If the retainer remov ed according to the removal step

above is attached to the pipe, clean and insert it

straight into the quick-connector till it clicks. After it

clicks, try pulling it out to make sure that it is not

drawn and is securely locked.

The retainer, once removed from the pipe, cannot be

reused. Just replace with a new retainer. Insert the new

retainer into the connector side until it clicks, and

connect the pipe as inserting it into the retainer until it

clicks.

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Assembling Advice

Application of engine oil or light oil to the pipe facilitates

connecting work. The work should be started

immediately after lubrication, since dust may stick to the

pipe surface to cause poor sealability if a long time

passes after lubrication.

Test/Inspection Afte r As se mbling

1. Reconnect the battery negative cable.

2. Turn the ignition key to the “ON" position and check

pump startup sound. As the pump is actuated to

raise fuel pressure, check and see fuel leak from the

piping sy stem.

3. Make sure of no fuel leakage by conducting the

above fuel leak check a few times.

4. Start the engine and make sure of stable idling

speed and normal vehicle run.The entry of dust

during the work may sometimes affect the fuel

injection system.

Fuel Pump Relay

General Description

In or der t o contr ol th e FPAS ope ra tion, t he FPAS re la y 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 rela y, again

causing the FPAS to feed fuel .

Fuel Tank

Fuel Tank and Associated Parts

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(1) Fuel Feed Port

(2) Fuel Tube/Quick Connector

(3) Fuel Return Port

(4) Fuel Pump and Sender Assembly

(5) Connector; Fuel Feed Pump

(6) Connector; Fuel Level Sender

(7) Fuel Pump Lock

(8) Hose; Evaporative Fuel

(9) Hose; Air Breather

(10) Hose; Fuel Filler

(11) Fuel Return Hose

(12) Fuel Feed Hose

(13) Band; Fuel Tank Asm Fixing

(14) Bolt; Fuel Tank Asm. Fixing

(15) Protector; Fuel Tank

(16) Fuel Tank Assembly

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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 fuel filler cap.

3.Support underneath of the fuel tank protector (15)

with a lifter.

4.Disconnect evaporative fuel hose (8) at the canister.

5.Disconnect fuel feed hose (12) and fuel return hose

(11) near the fuel filter.

NOTE: Plug both ends of the fuel hoses to prevent fuel

leakage.

6.Disconnect air breather hose (9) and fuel filler hose

(10) at the fuel filler neck.

NOTE: Cover fuel hose to prevent any dust entering.

7.Remove the four fuel tank assembly fixing bolts (14)

at four corners of the tank.

8.Let down the tank (16) and disconnect the wiring

connectors (5,6) and the emission hose at the

emission port on the fuel pump and sending

assembly (4).

9.Remove fuel tank assembly along with protectors

(15) .

10.Remove Fuel Tube/Quick Connector (2).

NOTE: Handling of fuel tube sure to refer “Fuel Tube/

Quick Connector Fittings" in this section.

11.Remove fuel pump and sender assembly (4) using

5–8840–2602–0.

12.Remove protectors (15) by removing the band fixing

bolts (13).

Installation

1.Install protectors (15) and tighten the band fixing

bolts to the specified torque.

Torque: 68 N·m (6.9 kg·m/50 lb ft)

2.Install fuel pump and sender (4) using 5–8840–

2602–0.

3.Install Fuel Tube/Quick Connector (2).

NOTE: Handling of fuel tube sure to refer “Fuel Tube/

Quick Connector Fittings" in this section.

4.Lift up fuel tank assembly (16) and connect the

emission hose to the emission port and the wiring

connectors (5,6) on the fuel pump and sending

assembly (4).

5.Install fuel tank assembly along with protectors and

tighten the four fixing bolts (14) to the specified

torque.

Torque: 68 N·m (6.9 kg·m/50 lb ft)

6.Connect fuel filler hose (10) and air breather hose

(9), and clip them firmly.

7.Connect fuel feed hose (12) and fuel return hose

(11), and clip them firmly.

8.Connect evaporative fuel hose (8).

9.Tighten fuel filler cap.

10.Connect battery ground cable.

Fuel Gage 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 sender

assembly.

Fuel Filler Cap

General Description

Fuel filler cap includes vacuum valve.

In case any high vacuum happen in tank, the valve

works to adjust the pressure to prevent the tank from

being damaged.

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Inspection

Check the seal ring in the filler cap for presence of any

abnormality and for seal condition.

Replace the filler cap, if abnormal.

CAUTION:

The fuel filler cap valve has characteristics.

A defective valve, no valve at all or a valve with the

wrong characteristics will do a lot of harm to engine

operating characteristics; be sure to use the same

fuel filler cap as installed in this vehicle.

(1) Vacuum Valve

(2) Fuel Filler Cap

Main Data and Specifications

Torque Specification

140RX014

Special Tool

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2602–0

Remover; fuel pump lock

(For S/W)