Isuzu KB P190. Manual - part 396

FUEL SYSTEM (4JK1/4JJ1)  6C-43 

Removal 

Note: When repairs to the fuel system have been 
completed, start the engine and check the fuel system
for loose connections or leakage. For the fuel system
diagnosis, see Section "Drivability and Emission". 

1.  Remove the fuel tank assembly (8). Refer to "Fuel

Tank Removal" in this section. 

2.  Disconnect the quick connector (1) of the fuel tube

from the fuel gauge unit. 

 

 
 
 

 

 

140R100035

3. Remove the retainer ring (3) from the fuel tank

with the removal tool 5-8840-2602-0. 

4.  Slowly remove the fuel gauge unit (6) from the fuel

tank as no bend float arm. 

Note: Cover opening for the fuel gauge unit on the fuel 
tank to prevent any dust entering. 

5. Discard the fuel gauge unit seal (7) because it

cannot be reused. 

 

 

Installation 

1.  Clean the seal surface of the fuel tank and the fuel 

gauge unit. 

Note: If there is dust on the seal surface, it can cause a
fuel leak. 

2. Install the new fuel gauge unit seal (7) to the 

opening of the fuel tank along the groove. 

3.  Slowly install the fuel gauge unit (6) into the fuel 

tank so there is no bend in the float arm. 

4.  Set the flange of the fuel gauge unit on the fuel 

gauge unit seal as mating convexity of the fuel 

gauge unit and reentrant of the fuel tank. 

5.  Slowly lock the retainer ring (3) to the fuel tank with 

the remover tool 5-8840-2602-0. 

6.  Connect the quick connector (1) of the fuel tube to 

the gauge unit. 

Note: Pull off the left checker of the fuel pipe. 

Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs. 

7.  Check for leak. 

Method of leak check. 

1. Plug the end of the quick connector and 

breather hose (Pull off the breather hose from 

fuel tank) and tighten fuel filler cap until at least 

one click is heard. 

2.  Apply soapy water around the fuel gauge unit 

seal area. 

3  Pressure air into the fuel tank from the end of 

the breather pipe at 34.3 kPa (0.35 kg / cm

2

 / 5

psi) over 15 seconds. 

4  Verify that no bubbles from around the fuel 

gauge unit seal area. 

8.  Install the fuel tank assembly (8). 

Note: Refer to "Install the fuel tank" in this section. 

 
 

 

 

Special Tool 

 

 

 

ILLUSTRATION 

PART NO. 

PART NAME 

 

 

 

 

5-8840-2602-0 

Remover: fuel pump 

retainer ring 

 

6C-44  FUEL SYSTEM (4JK1/4JJ1) 

Fuel Tube / Quick - Connector Fittings 

Precautions 

•  Do not light a match or create a flame. 
•  Keep flames away from your work area to prevent

flammable materials from catching fire. 

•  Disconnect the battery ground cable to prevent

electrical shorts. 

• Pre−treat the piping system or associated parts

from thermal damage or from spattering when

welding or similar heat

−generating work. 

 

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 electrolyte. 

Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was wiped on the
piping cannot be used. 

 

 
 
 

 

 

140R100032

Legend 

 1. O-ring 

 2. Port 

 3. Connector 

 4. Plastic 

Tube 

 

 

 

Removal 

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

the tank. Use compressed air to remove any dirt 

on the fuel quick connect fittings prior to 

disconnecting the fittings. When disconnecting the 

fuel pipe, cover the area with a cloth to prevent 

fuel from splashing as the fuel pipe may still have 

some pressure in it. 

 

 
 

 

 

140R100002

2.  For removal of the quick connector, hold the quick 

connector in one hand, and pull out the connector 

with the other hand while pressing the square 

release button of the connector, as illustrated. 

 

FUEL SYSTEM (4JK1/4JJ1)  6C-45 

Note: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light 
oil) and/or push and pull the connector until the pipe is
disconnected. 

 

 
 
 
 

 

 

140R100037

Cover the connectors that were removed with a plastic
bag, to prevent dust or rain water from entering. 

 

 

 

 

140R100028

 

 

Reuse of Quick-Connector 

•  Replace the port and connector if a scratch, dent 

or crack is found. 

•  Remove any dirt build up on the port when 

installing the connector. Replace the connector, if 

there is any rust, dents or scratches. 

•  After cleaning the port, insert it straight into the 

connector until it clicks. After it clicks, try pulling it 

out at 49 N (5 kg / 11 lb) to make sure that it is not 

drawn and is securely locked. 

 

 

 

 

140R100036

Assembling Advice 

By applying engine oil or light oil to the pipe, port makes 
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dust
from sticking to the pipe surface - which may decrease 
sealing ability). 

Test/Inspection After Assembling 

1.  Reconnect the battery negative cable. 

2. Start the engine and observe the engine idle 

speed. The presence of dirt in the fuel system may 

affect the fuel injection system. 

3.  Check for fuel leakage from the connector. 

 

 

 

 

 

6C-46  FUEL SYSTEM (4JK1/4JJ1) 

Filler Neck 

Removal 

1.  Remove the fuel tank. 

Note: Refer to "Fuel Tank" in this section. 

2.  Put a marking on the following points as the filler

neck assembly is restored. 
•  Each joint area of the hose (to restore axial

direction and insertion length of the hose) 

•  Each fasten area of the clamp (to restore axial

direction and position of the clamp) 

•  Each bolt in the clamp (to restore fasten length

of bolt in the clamp) 

•  The band clip (to restore position and fasten

length of the band clip) 

Note: Cover end of each hose and pipe to prevent any
dust entering. 

Installation 

1.  Align each marking and restore the following point.

•  Each joint area of the hose (Restore axial

direction and insertion length of the hose) 

•  Each fasten area of the clamp (Restore axial

direction and position of the clamp) 

Tightening torque: 2.5 N·m (0.25 kg

⋅⋅⋅⋅m /21.7 lb in)

 

Filler neck side except flat deck model. 

•  Each bolt in the clamp (Restore fasten length of

bolt in the clamp) 

Tightening torque: 2.5 N·m (0.25 kg

⋅⋅⋅⋅m /21.7 lb in)

 

Filler neck side except flat deck model. 

•  The band clip (Restore position and fasten

length of the band clip) 

2.  Install the fuel tank. 

Note: Refer to "Fuel Tank" in this section.