ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Electric Fuel Pump

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TESTING



See Figure 1



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Fig. Fig. 1: A fuel pressure gauge can be a valuable diagnostic tool

Except 2.2L Engine
  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the fuel line near the engine and install a fuel pressure gauge T-connector in the line.
  4.  
  5. Connect the fuel pressure gauge to the T-connector.
  6.  
  7. Start the engine and check the fuel pressure. Compare the pressure readings to the figures listed in the Tune-up Specifications chart in General Information & Maintenance .
  8.  

2.2L Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Leave the gauge attached to the pressure fitting on the fuel inlet pipe.
  4.  
  5. If disconnected during the fuel pressure relief procedure, reconnect the negative battery terminal.
  6.  
  7. Turn the ignition ON and listen for the pump to run (it should run for 2 seconds). If necessary, cycle the ignition OFF for 10 seconds and then ON again, in order to build maximum system pressure.
  8.  
  9. Note the fuel pressure with the pump RUNNING; it should be 41-47 psi (284-325 kPa). When the pump stops, pressure may vary slightly, then should hold steady.
  10.  

REMOVAL & INSTALLATION




CAUTION
Fuel is under high pressure; if the following steps are not followed the fuel could spray out and result in a fire hazard or possible injury.

Except 2.2L Engine

See Figure 2



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Fig. Fig. 2: Exploded view of the electric fuel pump

  1. Relieve the fuel pressure then disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely. Drain the fuel tank. Remove the undercover screws and undercover, if so equipped.
  4.  
  5. Unfasten all gas line hose connections and the fuel pump ground wire.
  6.  
  7. Remove the filler neck hose and clamp.
  8.  
  9. Remove the breather hose and clamp.
  10.  
  11. Disconnect the fuel tank hose-to-evaporator pipe. Place a suitable floor jack with a piece of wood on it under the fuel tank.
  12.  
  13. Remove the fuel tank mounting bolts and lower the tank from the vehicle. Disconnect the hose from the pump to the fuel filter.
  14.  
  15. Remove the fuel pump bracket plate and fuel pump as an assembly.
  16.  
  17. Remove the pump bracket, rubber cushion and fuel pump filter.
  18.  

To install:
  1. Install the pump to the bracket and rubber cushion. Install the fuel pump filter.
  2.  
  3. Install the fuel pump bracket plate and fuel pump as an assembly.
  4.  
  5. Raise the tank and connect the hoses. Fasten the tank straps.
  6.  
  7. Connect the fuel tank hose-to-evaporator pipe.
  8.  
  9. Install the breather hose and clamp.
  10.  
  11. Connect the fuel pump ground wire. Install the undercover and screws, if equipped.
  12.  
  13. Lower the vehicle safely. Refill the fuel tank and check for leaks.
  14.  
  15. Connect the negative battery cable and check operation.
  16.  

2.2L Engines

See Figures 3, 4, 5 and 6



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Fig. Fig. 3: Fuel pump used on 2.2L engines



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Fig. Fig. 4: A special tool is usually available to remove or install the fuel pump locking cam

t

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Fig. Fig. 5: A brass drift and hammer can be used to loosen the locking cam



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Fig. Fig. 6: Once the locking cam is released, it can be removed to free the pump

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the fuel tank, then remove it from the vehicle. Refer to the procedure later in this section for details.
  6.  
  7. Using fuel gauge sending unit retaining cam tool No. J-24187 or J-36608 (or equivalent) or a brass drift and a hammer, remove the cam locking ring (fuel sending unit) by twisting counterclockwise. With the locking ring released, carefully lift the sending unit from the fuel tank.
  8.  
  9. Remove the fuel pump from the fuel sending unit, by performing the following procedures:
    1. Pull the fuel pump up into the mounting tube, while pulling outward (away) from the bottom support.
    2.  

  10.  

When removing the fuel pump from the sending unit, be careful not to damage the rubber insulator and the strainer.

    1. When the pump assembly is clear of the bottom support, pull it out of the rubber connector.
    2.  


To install:
  1. Inspect the fuel pump hose and bottom sound insulator for signs of deterioration; replace, as necessary.
  2.  
  3. Push the fuel pump onto the sending tube.
  4.  
  5. Using a new sending unit-to-fuel tank O-ring, carefully lower the sending unit/fuel pump assembly into the fuel tank.
  6.  

When installing the sending unit, be careful not to fold or twist the fuel strainer, or it may restrict the fuel flow.

  1. Secure the sending unit by turning or driving the lockring clockwise and into position under the tabs.
  2.  
  3. Install the fuel tank assembly to the vehicle, then add fuel.
  4.  
  5. Connect the negative battery cable and check for proper pump operation.
  6.  

 
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