Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 1336
6E1–420
RODEO Y22SE 2.2L ENGINE DRIVEABILITY AND EMISSION
Inspection Procedure
Inspect in–tank fuel filter for tears, damage or evidence of
dirt derbies or water in the fuel. If any of these condition
exist, replace the in–tank fuel filter.
041RX003
Installation Procedure
1. Insert the fuel pump assembly into fuel tank and place
them at its position.
041RX002
2. Using J–39763, twist fuel pump assembly clock wise
into the lock.
901RX036
3. Install the fuel tank. Refer to Fuel Tank Installation
Procedure.
4. Install the fuel pump relay.
5. Connect the negative battery cable.
041RX004
6E1–421
RODEO Y22SE 2.2L ENGINE DRIVEABILITY AND EMISSION
Fuel Pump Relay
Removal Procedure
1. Remove the fuse and relay box cover located right
side of engine room.
2. Determine correct relay by consulting to the diagram
on the cover.
3. Insert a small screwdriver or use thumb pressure to
release the retainer of the relay.
4. Pull the relay straight up and out of the fuse and relay
box.
Installation Procedure
1. Inserts the relay into the correct place in the fuse and
relay box with the catch slot aligned to retainer.
2. Press down until the catch of retainer engages.
3. Install fuse and relay box cover.
014RW089
Fuel Rail Assembly
Removal Procedure
NOTE:
D
Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminal and the injector spray tips.
D
Fitting should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passage.
IMPORTANT:
An eight–digit identification number is
stamped on side of the fuel rail. Refer to this number when
you service the fuel rail or when a replacement part is
required.
014RX035
1. Depressurize the fuel system. Refer to Fuel Pressure
Relief Procedure.
2. Disconnect the fuel inlet at the rear of the engine.
3. Disconnect the fuel return line at front of the engine.
4. Disconnect the injector electrical connectors.
5. Remove the nuts holding wiring harness onto fuel rail.
6. Remove the bolts retaining fuel rail to the intake
manifold.
Lift up the injectors carefully to separate them from intake
manifold.
Lift up the fuel rail with injectors as assembly. Do not sep-
arate the fuel injectors from fuel rail.
If an injector become separated from fuel rail, injector
backup O–ring and injector retainer clip must be replaced.
Drain residual fuel from fuel rail into an approved contain-
er.
014RX036
6E1–422
RODEO Y22SE 2.2L ENGINE DRIVEABILITY AND EMISSION
7. If removal of fuel pressure regulator is necessary.
Refer to Fuel Pressure Regulator Removal
Procedure.
8. If removal of fuel injector is necessary. Refer to Fuel
Injectors Removal Procedure.
014RX037
Installation Procedure
1. Install the fuel injectors if necessary. Refer to Fuel
Injector Installation Procedure.
2. Install the fuel pressure regulator if necessary. Refer
to Fuel Pressure Regulator Installation Procedure.
3. Place the fuel injector rail assembly on the manifold
and insert the injectors into each port by pushing fuel
rail.
014RX037
4. Install two fuel rail retaining bolts. Tighten fuel rail
retaining bolts to 19 Nm (14 lb ft)
5. Place wiring harness in its place and secure it with two
nuts.
6. Connect electrical connector to each fuel injector.
014RX036
7. Connect the fuel supply line securely. Do not over
tighten.
8. Connect the fuel return line securely. Do not over
tighten.
9. Connect the negative battery cable.
10. Crank the engine until it start. Cranking the engine
may take longer than usual due to trapped air in the
fuel system. Check for leak. If fuel leak is observed,
stop engine immediately. Before correct fuel leak, be
sure to depressurize system again.
014RX035
6E1–423
RODEO Y22SE 2.2L ENGINE DRIVEABILITY AND EMISSION
Fuel Tank
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove fuel filer cap.
3. Drain the fuel from fuel filler neck.
4. Disconnect the fuel filler hose at fuel tank.
5. Disconnect the air breather hose at the fuel tank.
6. Disconnect the evaporator hose at the fuel tank.
7. Hold entire fuel tank at the bottom with stands.
8. Disconnect fuel supply lines and fuel return line at
near the fuel filter inside of body frame.
041RX005
9. Remove four bolts (two in front and two in rear)
holding fuel tank to the frame.
10. Lower tank assembly from the vehicle a little to make
access space on top.
11. Disconnect two electrical connectors at fuel pump.
041RX006
12. Remove fuel tank assembly from the vehicle.
13. Remove four nuts retaining tank under guard to the
tank.
14. Remove the tank from the guard.
041RX002
Installation Procedure
1. Secure fuel tank into under guard with four retaining
bolts, if necessary.
2. Place the fuel tank assembly onto stands.
3. Lift the fuel tank assembly near the position.
4. Connect two electrical connectors at fuel pump.
5. Lift the fuel pump to its position and secure it with four
mounting bolts. Make sure that all hoses and fuel
lines are out of way between the fuel tank and the fuel
tank bracket. Tighten the fuel tank retaining bolts to
36 Nm (27 lb ft).
041RX007
6. Connect fuel supply and return lines.
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