Isuzu Trooper (1998-2002 year). Manual - part 533

6E–502

6VE1 3.5 ENGINE DRIVEABILITY AND EMISSIONS

3. Disconnect the fuel hose from the fuel filter on the

engine side.

4. Disconnect the fuel hose from the fuel filter on the fuel

tank side.

5. Remove the bolt on the fuel filter holder.

041RW003

Legend

(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter

6. Remove the fuel filter.

Inspection Procedure

1. Replace the fuel filter when the following occur:

D

Fuel leaks from the fuel filter body.

D

The fuel filter body is damaged.

D

The fuel filter is clogged with dirt or sediment.

2. If the drain hole is clogged, clean the drain.

060R200242

Installation Procedure

1. Install the fuel filter in the correct direction.
2. Install the bolt on the fuel filter holder.

Tighten

D

Tighten the screws to 20 N·m (14 lb ft.).

3. Connect the fuel hose on the engine side.
4. Connect the fuel hose on the fuel tank side.

041RW003

Legend

(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter

5. Install the fuel filler cap.

060R200219

6. Connect the negative battery cable.

6E–503

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel Gauge Unit

Removal Procedure

Refer to 

Fuel Tank section.

060R200245

Fuel Injectors

Removal Procedure

NOTE: If the fuel injectors are leaking, the engine oil may
be contaminated with fuel.  Check the oil for signs of
contamination and change the oil and the filter if
necessary.

NOTE: Use care in removing the fuel injectors in order to
prevent damage to the fuel injector electrical connector
pins or the fuel injector nozzles.  The fuel injector is an
electrical component and should not be immersed in any
type of cleaner as this may damage the fuel injector.

IMPORTANT:

Fuel injectors are serviced as a complete

assembly only.

1. Disconnect the negative battery cable.
2. Remove the common chamber.  Refer to 

Common

Chamber in Engine Mechanical section.

3. Remove the fuel rail.  Refer to 

Fuel Rail section.

014RW164

4. Remove the injector retainer clip. 

040RY00001

5. Remove the fuel injector assembly.
6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .

Inspection Procedure

1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before

installation.

Installation Procedure

1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.

6E–504

6VE1 3.5 ENGINE DRIVEABILITY AND EMISSIONS

3. Install the fuel injector on the fuel rail.

040RY00001

4. Use new fuel injector retainer clips to retain the fuel

injector to the fuel rail.

5. Coat the end of the fuel injector with gasoline.
6. Install the fuel rail.  Refer to 

Fuel Rail section.

014RW164

7. Install the common chamber.  Refer to 

Common

Chamber in Engine Mechanical section.

8. Install the engine cover.
9. Connect the negative battery cable.

Fuel Metering System

Fuel Pressure Relief Procedure

CAUTION: To reduce the risk of fire and personal
injury, there are necessary to relieve the fuel system
pressure before filler and gauge unit servicing the
fuel system components.

CAUTION: After  relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections.  Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before you disconnect the fittings.  The
towels will absorb any fuel that may leak out.  When
the disconnect is completed, place the towel in an
approved container.

1. Remove the fuel cap.
2. Remove the fuel pump relay from the underhood

relay box.  Refer to 

Fuel Pump Relay section.

060R200195

3. Start the engine and allow it to stall.
4. Crank the engine for 30 seconds.
5. Disconnect the negative battery cable.

6E–505

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel Pump Assembly

Removal Procedure

Refer to 

Fuel Tank section.

060R200246

Fuel Pump Relay

Removal Procedure

1. Remove the fuse and relay box cover from under the

hood.

2. Consult the diagram on the cover to determine which

is the correct relay.

3. Insert a small screwdriver into the catch slot on the

forward side of the fuel pump relay.

D

The screwdriver blade will release the catch inside.

D08RY00291

4. Pull the relay straight up and out of the fuse and relay

box.

060R200195

Installation Procedure

1. Insert the relay into the correct place in the fuse and

relay box with the catch slot facing forward.

2. Press down until the catch engages.

D

An audible “click” will be heard.

060R200195

3. Install the fuse and relay box cover.