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Home >> Isuzu >> 2004 >> Ascender S, 4WD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls (Introduction) - 4.2L >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Fuel Tank & Related Components
    GM887435Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, position and support the fuel tank.
  2. Connect the fuel sender electrical connector (1).
    3. Fig 2: Locating Fuel Tank Components
    GM887432Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel tank straps (2).
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel tank strap attaching bolts (1).

    Tighten:  Tighten the bolts to 32 N.m (24 lb ft).

    5. Fig 3: Locating Fuel Return Pipe, Fuel Feed Pipe & EVAP Purge Pipe
    GM893021Courtesy of GENERAL MOTORS CORP.
  5. Remove the caps from the fuel and EVAP pipes.
  6. Connect the fuel return pipe, the fuel feed pipe and the EVAP purge pipe (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 4: View Of Fuel Tank & Related Components
    GM887435Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel tank pressure sensor electrical connector (3).
  8. Connect the EVAP vent valve electrical connector (2).
    9. Fig 5: Identifying Fuel Pipe/Hose Components
    GM730806Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel fill hose (2) to the fuel tank.

    Tighten:  Tighten the fuel fill hose clamp (1) to 2.5 N.m (22 lb in).

  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel filler cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  14. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  15. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  16. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (Short Wheelbase) or Fuel Tank Shield Replacement (Long Wheelbase) in Frame and Underbody.
  17. Install the frame brace. Refer to Frame Brace Replacement (Short Wheelbase) or Frame Brace Replacement (Long Wheelbase) in Frame and Underbody.
  18. Lower the vehicle.
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