Isuzu Trooper (1998-2002 year). Manual - part 641

6E–212

4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS

Installation Procedure

1. Install the AP sensor to the accelerator pedal

assembly.

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2. Install the accelerator pedal assembly to the

bulkhead.

3. Connect the electrical connector to the AP sensor.

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4. Connect the negative battery cable.

Accelerator Pedal Replacement

Removal Procedure

1. Disconnect the negative battery cable.
2. Disconnect the electrical connector to the AP sensor.

3. Remove the bolts and the accelerator pedal

assembly from the bulkhead.

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4. Remove the bolts and AP sensor from the accelerator

pedal assembly.

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Installation Procedure

1. Install the AP sensor to the accelerator pedal

assembly.

2. Install the accelerator pedal assembly to the

bulkhead.

6E–213

4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS

3. Connect the electrical connector to the AP sensor.

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4. Connect the negative battery cable.

Fuel Filter Cap

General Description

The fuel filler cap includes a vacuum valve and a pressure
valve.
If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
prevent damage to the tank at the EGR valve.

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Inspection Procedure

NOTE: Replace the fuel filler cap with the same type of
filler cap that was originally installed on the vehicle.

D

Check the seal ring in the filler cap for any abnormality
and for seal condition.

D

Replace the filler cap if any abnormality is found.

Fuel Filter

Removal and Installation Procedure

Refer to the Engine fuel in the 4JX1 Engine section.

Fuel Gauge Unit

Removal Procedure

1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank.

Tighten

D

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

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4. Disconnect the wiring connector from the fuel gauge

unit.

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5. Remove the fuel gauge unit retaining screws.

6E–214

4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS

6. Remove the fuel gauge unit.

D

Cover or plug the fuel tank to prevent dust, dirt, or
debris from entering the tank.

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Installation Procedure

1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.

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3. Connect the wiring connector to the fuel gauge unit.

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4. Fill the fuel tank with fuel.

D

Tighten the fuel filler cap.

D

Check for leaks at the fuel gauge unit gasket.

5. Connect the negative battery cable.

Fuel Injectors

Removal and Installation Procedure

Refer to Engine Fuel in 4JX1 Engine Section.

Fuel Temperature Sensor

Removal Procedure

CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before 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 disconnecting 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. Disconnect the negative battery cable.
2. Remove the intercooler assembly.
3. Remove the cylinder head. Refer to engine

mechanical section.

6E–215

4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS

4. Remove the rear side engine hanger.

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5. Remove the fuel return adapter.

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6. Remove the fuel pressure sensor from the fuel return

adapter.

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Installation Procedure

1. Install the fuel pressure sensor in the fuel return

adapter.

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