GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2000 🢒 S/T Isuzu - 2WD 🢒 Engine 🢒 Engine Controls - 4.3L 🢒 Fuel Tank Replacement

Removal Procedure
    • J 34730-1A Fuel Pressure Gauge
    • J 39765 Fuel Sender Lock Nut Wrench

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 616679 Size: SH
  4. Loosen the fuel fill hose clamp (4) and the vent hose clamp (2) at the fuel tank fill and vent pipe (3).
  5. Disconnect the fuel fill hose and the vent hose from the fuel tank fill and vent pipe (3).
  6. Support the fuel tank.

    7. Object Number: 617032 Size: SH
  7. Remove the fuel tank front shield (4) (without underbody shield package).

    8. Object Number: 617041 Size: SH
  8. Remove the fuel tank shield (4 wheel drive with underbody shield package).

    9. Object Number: 616757 Size: SH
  9. Support the fuel tank.
  10. Remove the fuel tank front strap (1).

    11. Object Number: 616751 Size: SH
  11. Remove the fuel tank rear strap (4).

    12. Notice: Ensure that the connections to both roll over valves are disconnected prior to lowering the fuel tank more than 51 mm (2 in). The roll over valves are located at both the front and rear of the fuel tank.

  12. Disconnect the EVAP pipes from the rollover valves.

    13. Notice: Use extreme care when lowering the fuel tank. The fuel sender is made of plastic. Lowering the fuel tank may damage the fuel sender.

  13. Carefully lower the fuel tank.

    14. Object Number: 331713 Size: SH
  14. Disconnect the fuel pressure sensor and the fuel sender electrical connectors.
  15. Disconnect the fuel feed pipe, the fuel return pipe, and the EVAP pipe at the fuel sender.

    16. Object Number: 331709 Size: SH
  16. Remove the fuel sender from the fuel tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 331709 Size: SH
  1. Install the fuel sender into the fuel tank. Refer to Fuel Sender Assembly Replacement .

    2. Object Number: 616741 Size: SH
  2. Install the fuel tank insulators.

    3. Object Number: 331713 Size: SH
  3. With the aid of an assistant, position and support the fuel tank.
  4. Raise the fuel tank.
  5. Connect the fuel feed pipe, the fuel return pipe, and the EVAP pipe at the fuel sender.
  6. Connect the fuel pressure sensor and the fuel sender electrical connectors.
  7. Connect the EVAP pipes to the rollover valves.

    8. Object Number: 616754 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Important: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.

  8. Install the rear fuel tank strap (4) and the protector (2) to the crossmember with the bolt (3) and the retainer (1).

    9. Tighten
    Tighten the fuel tank strap bolt to 18 N·m (13 lb ft).


    Object Number: 616751 Size: SH
  9. Install the rear fuel tank strap to frame bolt.

    10. Tighten
    Tighten the fuel tank strap bolt to 18 N·m (13 lb ft).


    Object Number: 617034 Size: SH
  10. Install the rear fuel tank shield (without underbody shield package).

    11. Object Number: 617037 Size: SH
  11. Push the shield (2) onto the horizontal flange of the fuel tank (1).
  12. The shield (2) is designed with interference to the bottom of the fuel tank (3).

    13. Object Number: 617032 Size: SH
  13. Install the fuel tank front shield (4), washer (2), and nut (3) (without underbody shield package).

    14. Tighten
    Tighten the fuel tank shield nut to 25 N·m (18 lb ft).


    Object Number: 617041 Size: SH
  14. Install the fuel tank shield to the fuel tank strap bolt (5) with the washer (3) and the nut (4) (4 wheel drive with underbody shield package).
  15. Install the fuel tank shield to frame bolts (2).

    16. Tighten

    1. Tighten the fuel tank shield bolts (2) to 11 N·m (97 lb in).
    2. Tighten the fuel tank shield nut (4) to 25 N·m (18 lb ft).
  16. Install the fuel tank shield to crossmember bolts (1) and nuts (6).

    17. Tighten
    Tighten the fuel tank shield bolts and nuts to 23 N·m (17 lb ft).


    Object Number: 616996 Size: SH
  17. Connect the fuel fill hose and the vent hose to the fuel tank fill and vent pipe (3).

    18. Tighten

        • Tighten the fuel fill hose clamp (4) to 2.5 N·m (22 lb in).
        • Tighten the vent hose clamp (2) to 1.7 N·m (15 lb in).
  18. Lower the vehicle.
  19. Refill the fuel tank.
  20. Install the fuel tank filler cap.
  21. Connect the negative battery cable.
  22. Inspect for leaks.
    23. 22.1. Turn the ignition switch ON for 2 seconds.
    22.2. Turn the ignition switch OFF for 10 seconds.
    22.3. Turn the ignition switch ON.
    22.4. Inspect for fuel leaks.