Replacing Fuel Pump In Isuzu Rodeo: Step-By-Step Guide

If you need to replace the fuel pump on your 2000 Isuzu Rodeo, there are a few things you should know. Firstly, it is recommended to have the fuel tank almost empty before starting, as it will be easier to remove. Some models have two round rings on top of the tank, one for the sender unit and the other for the fuel pump, while others have both incorporated into one ring. You will need to remove the ring in the middle section of the tank, being careful not to bend the float arm for the sender unit. There are also video guides on YouTube that can walk you through the process step-by-step.

Ensure the fuel tank is near empty

To ensure the fuel tank is near empty, follow these steps:

First, remove the fuel filler cap. Then, use a hand-operated pump device to drain as much fuel as possible through the fuel filler pipe. It is important to do this slowly and carefully to avoid forcing the pump device, as this can cause the fuel pump to dislocate from the fuel sender assembly. Once you have drained as much fuel as possible, install the fuel filler cap.

The next step is to remove the negative battery cable. This is followed by draining the fuel tank. You will then need to raise the vehicle and suitably support it. With the aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps.

By ensuring that the fuel tank is near empty, you can proceed with the fuel pump replacement process on your 2000 Isuzu Rodeo.

Disconnect AC & fuel line

To disconnect the AC and fuel lines on a 2000 Isuzu Rodeo, follow these steps:

First, remove the screws holding the driver-side kick panel in place, including the two behind the hood release lever and one near the transmission tunnel. Pull the top edge of the panel to remove it. Disconnect the power mirror controls and security light flasher if your vehicle is equipped with them.

Next, remove the screws from the bottom of the dash surround, including the two under the left vent and one between the steering column and clock module. Then, remove the two screws at the top in front of the gauge cluster. Use a long Phillips or JIS screwdriver for this step. Carefully pull the dash surround rearward. Disconnect all the switches on the left side, including the Cruise Control Switch, 4WD switch, and Fog Light Switch. Disconnect the dash dimmer, clock, rear wiper, defroster, and hazard lights on the right side.

Now you will have access to the factory screws holding the AC controls in place. Remove these screws, but do not pull out the climate control unit yet. It is still connected by cables tucked under and behind the dash. Remove the glovebox or squeeze the sides to drop it down for easier access.

To disconnect the AC lines, first, locate the temperature flapper on the passenger side. This is tucked up behind the left side of the passenger footwell. For 1998-1999 models, the recirculate flapper is located behind the passenger airbag and is cable-actuated. For 2000+ models, this is electronically controlled. Disconnect the cables from the plastic levers using a metal pick tool or a flathead screwdriver. Be careful not to damage the plastic lever. Lift up on the clamp holding the cable sleeve. Once all cables are disconnected, you can pull out the AC controls and disconnect the electrical connector.

To disconnect the fuel line, follow these steps:

Relieve the fuel system pressure and drain the fuel tank. Remove the negative battery cable, fuel filler and vent hoses, fuel tank skid plate, and fuel tank wiring connectors. Disconnect the fuel supply and return lines from the fuel tank. The fuel pump assembly can now be removed.

Remove the fuel tank/sending unit lock ring

To remove the fuel tank/sending unit lock ring on a 2000 Isuzu Rodeo, you must first ensure that the fuel tank is almost empty, making it easier to remove. Some models have two round rings on top of the tank, one is the sender unit (for the gauge), and the other is the fuel pump. Other models have one round ring that combines both functions.

To remove the lock ring, you will need to locate it near the middle section of the tank. Be careful not to bend the float arm for the sender unit if it is a twin-type (sender and fuel pump in one) model. Once you have located the lock ring, use a suitable tool to loosen and remove it. You may need a specialized tool for this task, such as a lock ring plier or a fuel tank lock ring removal tool. It is important to work carefully in order to avoid any damage to the surrounding components.

After removing the lock ring, you can proceed to the next step, which may involve lifting or lowering the fuel tank to access the fuel pump. Remember to refer to a reliable repair manual or seek assistance from a qualified mechanic if you are unsure about any part of the process. Safety should always be a top priority when working on your vehicle.

Remove the fuel pump sender unit

To remove the fuel pump sender unit on a 2000 Isuzu Rodeo, you will first need to relieve the fuel system pressure and drain the fuel tank. You can do this by removing the fuel filler cap and using a hand-operated pump device to drain as much fuel through the fuel filler pipe as possible.

Next, remove the negative battery cable, and then the fuel tank shield. With the aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps. Remove the fuel tank pressure sensor connector, the fuel sender electrical connector, and the hoses from the fuel tank sender.

At this point, you should be able to remove the fuel tank from the vehicle. Once the tank is out, remove the sound insulators and the fuel sender assembly from the tank.

It is important to note that you should be very careful when performing this task to avoid any potential safety hazards. Do not smoke, be around any open flames, or use electric lighting. If you have never done this before, it may be best to have a mechanic perform this task.

Install the new fuel pump

To install a new fuel pump on your 2000 Isuzu Rodeo, you will first need to remove the fuel tank. Ensure the tank is almost empty so that it is not too heavy to remove. Some models have two round rings on top of the tank: one is the sender unit (for the gauge), and the other incorporates the fuel pump. Other models have one round ring that incorporates both. Remove the one near the middle section of the tank, being careful not to bend the float arm for the sender unit if it is a twin type (sender and fuel pump in one).

Once the fuel tank is removed, you can access the fuel pump and sender unit. Disconnect the electrical connector and any fuel lines attached to the pump. You may need to remove any retaining clips or brackets holding the pump in place. Take note of the orientation of the pump and any markings on the surrounding components to ensure that you install the new pump correctly.

Finally, re-install the fuel tank and fill it with fuel. Start the engine and check for any leaks or unusual noises. If everything appears to be in order, you have successfully installed the new fuel pump.

Frequently asked questions