Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Service manual - part 807

6C–1

ENGINE FUEL (6VD1 3.2L)

ENGINE

ENGINE FUEL

CONTENTS

Service Precaution

6C–1

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General Description

6C–2

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Fuel Metering

6C–3

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Fuel Filter

6C–4

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Removal

6C–4

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Inspection

6C–4

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Installation

6C–4

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Inspection

6C–4

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In–Tank Fuel Filter

6C–4

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Fuel Pump Flow Test

6C–4

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Fuel Pump

6C–5

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Fuel Pump and Associated Parts

6C–5

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Removal

6C–5

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Installation

6C–5

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Fuel Pump Relay

6C–6

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General Description

6C–6

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Fuel Tank

6C–6

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Fuel Tank and Associated Parts

6C–6

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Removal

6C–6

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Installation

6C–7

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Fuel Gauge Unit

6C–7

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Removal and Installation

6C–7

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Fuel Filler Cap

6C–7

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General Description

6C–7

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Inspection

6C–7

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Main Data and Specifications

6C–8

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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 force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

INDEX

6C–2

ENGINE FUEL (6VD1 3.2L)

General Description

060RW245

Legend

(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump Assembly
(5) Fuel Filter
(6) Fuel Rail Right
(7) Intake Air Port Right Bank
(8) Fuel Rail Left

(9) Intake Air Port Left Bank

(10) Fuel Pressure Control Valve

(11) Common Chamber

(12) Duty Solenoid Valve
(13) Throttle Valve
(14) Canister
(15) Fuel Gauge
(16) Check Valve

6C–3

ENGINE FUEL (6VD1 3.2L)

When working on the fuel system, there are several
things to keep in mind:

D

Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.

D

Always keep a dry chemical (Class B) fire
extinguisher near the work area.

D

Replace all pipes with the same pipe and fittings that
were removed.

D

Clean and inspect “O” rings. Replace if required.

D

Always relieve the line pressure before servicing any
fuel system components.

D

Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.

D

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
emission control system and could result in loss 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 vapors to the atmosphere.

Fuel Metering

The Engine Control Module (ECM) 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 Barometric Pressure (BARO) sensor measures the
changes in the barometric pressure which result from
engine load and speed changes, which the BARO 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 ECM.
With receipt of the signals sent from the BARO sensor,
Intake Air Temperature sensor and others, the ECM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
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.
Two interchangeable “O” rings are used on the injector
that must be replaced when the injectors are removed.
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 vapors 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.

6C–4

ENGINE FUEL (6VD1 3.2L)

Fuel Filter

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. Remove Fuel filler cap.
3. Disconnect fuel hoses from fuel filter on both engine

side and fuel tank side.

4. Fuel filter fixing bolt.

D

Remove the fuel filter fixing bolt on fuel filter holder.

5. Remove fuel filter.

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 of receive rubber and if it is clogged

with dust, clean it up 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(1) and fuel tank

side(2).

041RW001

4. Install fuel filler cap
5. Connect the battery ground cable.

Inspection

After installation, start engine and check for fuel leakage.

In–Tank Fuel Filter

The filter is located on the lower end of 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 selfcleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.

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.

060RW086

CAUTION: Never generate sparks when connecting
a jumper wire.

Delivery

Delivery

15 seconds

0.38 liters minimum

If the measure value is out of standard, conduct the
pressure test.

Pressure test

For the pressure test to the fuel system, see Section 6E
“Fuel Control System”.