Sylvie Willis
The Isuzu NPR truck is equipped with a 38.6-gallon in-frame fuel tank, which is placed between the rear frame rails. While the tank's position keeps it free from clutter and interference with body mounts, it may need to be removed in certain situations, such as when the wrong type of fuel has been added. If the vehicle has been run, the fuel system should be disassembled, and the tank manually removed, drained, and flushed with diesel to prevent engine damage. This process requires mechanical expertise, and it is recommended to consult a certified mechanic for advice.
| Characteristics | Values |
|---|---|
| Fuel tank removal | The tank must be removed and manually drained to ensure all gasoline is removed. |
| Siphoning | Siphoning may not empty the tank completely. |
| Fuel filter | Replacing the fuel filter is recommended when removing the tank. |
| Running out of fuel | Running the Isuzu NPR truck out of fuel can cause significant problems and may require mechanical experience to fix. |
| Towing | In case of running out of fuel, the truck should be towed to a dealer or repair service. |
| Refuelling | At least five gallons of clean diesel fuel should be put back into the tank. |
| Fuel pump | Locate and loosen the bleeder bolt on the fuel primer pump, then pump until fuel comes out. |
| Engine | Crank the engine for a minute, and it should start. |
| Fuel line | Loosen the nut to the supply line at the fuel rail. |
| Tank bolts | There are two bolts on the front of the tank and three bolts/nuts on the rear. |
| Tank replacement | Replacement fuel tanks are available from Boyd Welding LLC in aluminum and diesel options. |
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What You'll Learn
Siphoning the tank
It is important to note that siphoning gas is illegal in some states and can also damage your vehicle if not done correctly. Inhaling gasoline vapours can cause dizziness, nausea, and even respiratory problems, so it is best to use a manual siphon pump or an electric pump to transfer the gas safely.
If you are going to siphon the tank, you will need a length of tubing that is long enough to reach from the gas tank to a container on the ground, a container to hold the gas, and a pair of pliers. The fuel tank is usually located beneath the car, near the rear wheels. Insert one end of the tubing into the gas tank through the fuel filler neck. Make sure the tubing is securely in place and that it reaches the bottom of the tank.
Then, insert the other end of the siphon hose into a container. Using a small air compressor or bike pump, create pressure in the container. This pressure will force the gas out of the tank and into the container. It is important to note that this method can be dangerous if not done properly, as too much pressure can cause the gas tank to rupture or explode.
Alternatively, you can use a manual or electric pump to create suction and transfer the gas. This method is safer and more efficient, but it may not be available in an emergency situation.
Remember, siphoning gas can be dangerous and illegal in some areas. Always use caution and follow proper safety procedures when attempting to siphon gas.
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Removing and draining the tank
To remove and drain the fuel tank of an NPR Isuzu truck, there are several steps you can take to ensure a safe and efficient process. Firstly, it is important to note that simply siphoning the tank may not be sufficient, as fuel lines and injection systems may still contain gasoline, which can cause engine damage. Therefore, removing and manually draining the tank is a more comprehensive approach.
Before beginning the process, ensure that you have the necessary tools and safety equipment, such as gloves and eye protection, and place the vehicle on a level surface. Then, locate the fuel tank and identify the bolts securing it in place. There may be two bolts on the front and three bolts/nuts on the rear, as well as a strap around the tank. Disconnect any sender wires, loosen the clamp around the filler hose, and adjust the clamps on the supply and return lines.
Once the connections have been loosened, you may need to carefully lower or remove any components blocking access to the tank, such as the cab or bed of the truck. It is important to refer to the vehicle's repair manual or seek advice from a certified mechanic if you are unsure about any steps. After gaining clear access to the fuel tank, carefully remove the bolts and nuts securing the tank, ensuring that you have a secure grip on the tank to prevent it from falling unexpectedly.
With the fuel tank bolts removed, carefully lower and remove the tank, being cautious of any remaining fuel or residue. Place the tank in a safe and appropriate container or area to proceed with the draining process. If you are replacing the tank, ensure that the new tank is an exact fit and that all opening and mounting holes align correctly. Finally, properly dispose of any drained fuel or residue according to local regulations and guidelines.
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Replacing the fuel filter
To replace the fuel filter of an Isuzu NPR truck, follow these steps:
Firstly, locate the fuel-water-separator. Place a suitable drain container beneath the fuel-water-separator drain valve. Loosen the petcock (drain valve) and allow it to drain completely. Once it has drained, tighten the fuel-water-separator petcock.
Next, locate the fuel filter. Place rags beneath the fuel filter canister to collect any fuel that leaks out when the filter is loosened. Remove the fuel filter from its mount by rotating it counterclockwise when looking at the bottom of the filter. Check that the fuel filter gasket was removed with the filter canister and is not stuck to the flange of the mount. Clean the fuel filter mounting flange with a lint-free cloth.
Now, fill the replacement fuel filter with clean diesel fuel or a diesel fuel additive. Do not use diesel fuel from the old filter. Lubricate the fuel filter gasket with clean diesel fuel or clean engine oil. Install the new fuel filter in reverse order, tightening it by hand. Do not use tools, as overtightening may compromise the gasket seal.
Locate the fuel filter bleed orifice at the top of the filter mount and loosen it. Place a rag over the bleed orifice, as fuel will seep out in the subsequent steps. Operate the plunger by pressing down and allowing it to travel back up. Repeat this until fuel begins to seep from the bleed orifice. Tighten the bolt once the fuel begins to flow from the bleed orifice. Push the plunger downwards and tighten it.
Finally, start the engine and let it run for several minutes. Check for fuel leaks at the fuel filter and fuel-water-separator. The engine may run rough and stall several times until full fuel prime is obtained, but this is normal.
Note: It is recommended to drain the fuel-water separator and replace the fuel filter every 13,000 miles, 12 months, or when there is a substantial amount of water in the separator bowl.
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Towing the truck to a dealer
If your Isuzu NPR truck has a fuel tank issue, such as filling it with the wrong fuel, you may need to get it towed to a dealer or repair service. The Isuzu NPR truck has a towing capacity of up to 18,000 pounds (GCWR), so you can expect to handle thousands of pounds of towing weight. This makes it a good choice for hauling heavy equipment or cargo.
When it comes to towing your truck, there are a few things to keep in mind. Firstly, ensure that you have the right tools and equipment for the job. This includes things like tow straps, chains, or a tow bar, as well as safety equipment like warning triangles or lights. Secondly, it's important to follow proper safety procedures when connecting the truck to the tow vehicle. This may involve attaching the tow strap or chain to the designated towing points on both vehicles and ensuring that all connections are secure.
Once the truck is connected to the tow vehicle, you'll need to decide on the best route to the dealer or repair shop. Consider factors such as distance, traffic conditions, and any weight or height restrictions that may apply to your tow vehicle and the Isuzu NPR truck. It's also important to drive cautiously and obey all traffic laws when towing a vehicle.
When you arrive at the dealer or repair service, they will be able to assess the issue with your fuel tank and provide you with options for repair or replacement. They may recommend siphoning the tank and refilling it with the correct fuel, or they may suggest removing the fuel tank and manually draining it to ensure all the incorrect fuel is removed. In some cases, they might suggest a fuel tank replacement, especially if there has been severe engine damage. Working with a professional mechanic will ensure that your truck is properly diagnosed and repaired, getting you back on the road safely.
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Re-priming the fuel supply pump
First, loosen the nut to the supply line at the fuel rail. Then, pump the fuel primer pump until you see fuel squirting from the nut. Ensure that you tighten the fuel line back down and lower your cab before proceeding. Next, turn the key to the 'on' position and let the engine crank for about 20 seconds. If it does not crank, stop and let the starter cool for two minutes before attempting to crank it again for 20 seconds. If it still does not crank, return to the fuel rail and loosen all four nuts to the lines going to the injectors by ½ - 2 full turns each.
If this does not work, there are a few other things you can try. One suggestion is to open the bleed screw on the filter head and pump until fuel comes out. You could also try gently pressurizing the tank with the output from a shop vac, which should drive the fuel up into the system and to the IP. If your Isuzu NPR truck has run out of diesel, you may need to disconnect the fuel line to the injector and use a vacuum pump to pull fuel through the supply line. Alternatively, you could try filling the fuel filter with Dexron II.
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