GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2005 🢒 Isuzu MD F-Series 🢒 Engine 🢒 Engine Controls - 7.8L 🢒 Fuel Tank Replacement

Removal Procedure
  1. Drain the fuel from the tank.
  2. Disconnect the fuel sender assembly electrical connector.
  3. Remove the nut and the fuel sender assembly ground lead from the fuel tank. Note the position of the ground lead for installation.

    4. Object Number: 724691 Size: SH
  4. Remove the fuel lines (1, 3) from the fuel sending unit (2). Refer to Metal Collar Quick Connect Fitting Service .

    5. Object Number: 318435 Size: SH
  5. Remove the nuts (2) and washers (1) from both fuel tank straps. Reposition the fuel tank straps in order to remove the fuel tank.
  6. Support the fuel tank with a suitable lifting device.
  7. Remove the fuel tank from the fuel tank supports.
  8. Remove the fuel sender assembly if replacing or servicing the tank. Refer to Fuel Sender Assembly Replacement .
  9. Remove the fuel cap chain retainer and fuel cap if fuel tank is being replaced.
  10. Purge the tank if the tank is being serviced.

Installation Procedure
  1. Install the fuel sender assembly if replacing or servicing the tank. Refer to Fuel Sender Assembly Replacement .
  2. Install fuel tank chain to the fuel tank with retainer, if removed.
  3. Install the fuel tank onto the fuel tank supports with the straps.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 318435 Size: SH
  4. Install the fuel tank strap nuts (2) and the washers (1).

    5. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).


    Object Number: 724691 Size: SH
  5. Install the fuel lines (1, 3) to the fuel sending unit (2). Refer to Metal Collar Quick Connect Fitting Service .
  6. Install the fuel tank ground lead to the stud with nut.

    7. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  7. Reconnect the fuel sender assembly electrical connector.
  8. Refill the fuel tank.
  9. Inspect for leaks.