Isuzu Ascender 2003-05

Removal & Installation

Print

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the frame brace.
  8.  
  9. Remove the fuel tank shield, if equipped.
  10.  
  11. Drain the fuel tank.
  12.  
  13. Disconnect the Evaporative emission (EVAP) canister fresh air pipe.
  14.  
  15. Disconnect the EVAP canister solenoid pipe.
  16.  
  17. Disconnect the EVAP purge pipe.

    Click image to see an enlarged view

    Fig. EVAP pipes

  18.  
  19. Disconnect the fuel filler pipe recirculation hose from the fuel tank.
  20.  
  21. Loosen the clamp securing the fuel fill pipe to the fuel tank.
  22.  
  23. Disconnect the fuel fill pipe from the fuel tank.

    Click image to see an enlarged view

    Fig. Fuel fill pipe removal

  24.  
  25. Disconnect the fuel feed pipe and EVAP pipe from the fuel tank.
  26.  
  27. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
  28.  
  29. Support the fuel tank.
  30.  
  31. Remove the fuel tank strap attaching bolts.
  32.  
  33. Remove the fuel tank straps.
  34.  
  35. Carefully lower the fuel tank.

    Click image to see an enlarged view

    Fig. Fuel tank removal

  36.  

To install:

  1. Support the fuel tank.
  2.  
  3. Connect the fuel sender electrical connector.
  4.  
  5. Connect the EVAP vent valve electrical connector.
  6.  
  7. Connect the fuel pressure sensor electrical connector.
  8.  
  9. Install the fuel tank straps.
  10.  
  11. Install the fuel tank strap attaching bolts.
  12.  
  13. Tighten the bolts to 24 ft. lbs. (32 Nm).
  14.  
  15. Remove the caps from the fuel and EVAP pipes.
  16.  
  17. Connect the fuel feed pipe and the EVAP pipe.
  18.  
  19. Connect the fuel fill pipe to the fuel tank.
  20.  
  21. Tighten the fuel fill hose clamp to 22 inch. lbs. (2.5 Nm).
  22.  
  23. Connect the fuel filler pipe recirculation hose to the fuel tank.
  24.  
  25. Connect the EVAP purge pipe.
  26.  
  27. Connect the EVAP canister solenoid pipe.
  28.  
  29. Connect the EVAP canister fresh air pipe.
  30.  
  31. Lower the vehicle.
  32.  
  33. Refill the fuel tank.
  34.  
  35. Install the fuel filler cap.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Raise the vehicle and inspect for leaks.
  40.  
  41. Install the fuel tank shield, if equipped.
  42.  
  43. Install the frame brace.
  44.  
  45. Lower the vehicle.
  46.  

 
label.common.footer.alt.autozoneLogo