Isuzu I-280, I-350 2005-06

Removal & Installation

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  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner.
  6.  
  7. Remove the left pickup box wheelhouse liner by removing the push-in retainers that attach the liner to the vehicle.
  8.  
  9. Disconnect the fuel filler hose (4) from the fuel tank (3).
  10.  
  11. Disconnect the Evaporative Emission (EVAP) hose (2) from the fuller vent tube (1).

    Click image to see an enlarged view

    Fig. Disconnecting fuel filler hose and Evaporative Emission (EVAP) hose

  12.  
  13. Disconnect the following electrical connectors from the fuel tank:

    Fuel tank pressure sensor (2)
     
    Fuel tank module (3)
     

  14.  
  15. Disengage the fuel wiring harness from the retainer (5) on the fuel tank.
  16.  
  17. Raise the vehicle fully.

    Click image to see an enlarged view

    Fig. Disconnecting Fuel tank pressure sensor, fuel tank module and fuel wiring harness

  18.  
  19. Disconnect the middle of the EVAP vapor pipe (1, 3) located between the fuel tank and the EVAP canister.

    Click image to see an enlarged view

    Fig. Disconnecting the middle of the EVAP vapor pipe

  20.  
  21. Disconnect the following from the chassis bundle (2, 3):
    WARNING
    Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.



    Fuel return hose (1)
     
    Fuel filter (4)
     



    Click image to see an enlarged view

    Fig. Disconnecting the fuel return hose and fuel filter

  22.  
  23. Remove the upper fuel tank strap bolt.
  24.  
  25. Remove the upper fuel tank strap.
  26.  
  27. Support the fuel tank.

    Click image to see an enlarged view

    Fig. Removing upper fuel tank strap bolt

  28.  
  29. Remove the lower fuel tank strap bolt.
  30.  
  31. Remove the lower fuel tank strap.
  32.  
  33. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
  34.  
  35. Place the fuel tank in a suitable work area.
  36.  

To install:

  1. With the aid of an assistant, carefully position and support the fuel tank to the vehicle.
  2.  
  3. Install the lower fuel tank strap.
  4.  
  5. Install the lower fuel tank strap bolt. Do not tighten the bolt at this time.
  6.  
  7. Install the upper fuel tank strap.
  8.  
  9. Install the upper fuel tank strap bolt. Tighten the fule tank strap bolts to 24 ft. lbs. (32 Nm).
  10.  
  11. Connect the following chassis bundle:

    Fuel return hose
     
    Fuel filter
     

  12.  
  13. Connect the middle of the EVAP vapor pipe located between the fuel tank and the EVAP canister.
  14.  
  15. Lower the vehicle only enough to gain access the fuel tank through the wheelhouse.
  16.  
  17. Connect the following electrical connectors to the fuel tank:

    Fuel tank pressure sensor
     
    Fuel tank module
     

  18.  
  19. Secure the fuel tank wiring harness to the retainer on the fuel tank.
  20.  
  21. Connect the fuel filler hose to the fuel tank. Tighten the fuel filler hose clamp to 22 inch lbs. (2.5 Nm).
  22.  
  23. Connect the EVAP hose to the filler vent tube.
  24.  
  25. Install the left pickup box wheelhouse liner.
  26.  
  27. Lower the vehicle.
  28.  
  29. Refill the fuel tank.
  30.  
  31. Install the fuel filler cap.
  32.  
  33. Inspect for leaks:
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition, with the engine OFF.
    6.  
    7. Inspect for fuel leaks.
    8.  

  34.  

 
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