Fuel Tank Assembly

WARNING: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

Fuel Tank Mounting:

REMOVAL:
1. Remove all fuel from the tank, see MAINTENANCE PROCEDURES.
2. Raise the vehicle.
3. Disconnect tank sender unit electrical connector.
4. Remove hoses from tank sending unit.
5. Support fuel tank and disconnect the two fuel tank retaining straps.
6. Lower tank enough to disconnect ground lead, if equipped.
7. Remove tank from vehicle.
8. Remove fuel level sender assembly attaching nuts (6), retaining flag, sender assembly and O-ring from fuel tank. Lift assembly from the fuel tank.
9. Remove sender unit from tank.

Fuel Pump/Fuel Gauge Sending Unit (typical):

Fuel Pump/Fuel Level Sender Replacement:

INSTALLATION:
1. Installation is the reverse of the removal with the following additional steps.
2. Always replace the O-ring gasket when the fuel pump/sending unit has been removed.

NOTE: Care should be taken not to fold over or twist the strainer when installing the sending unit, as this will restrict the fuel flow. Also, assure that the strainer does not block full travel of the float arm.

3. When reinstalling the fuel tank, be sure to install insulator pads on top of the tank to reduce rattle and other annoying noises.
4. Tighten the front fuel tank retaining strap bolts to 35 N-m (26 lb.ft). Tighten the rear strap bolts to 11 N-m (8 lb.ft).
5. When completed, fill the tank and inspect the entire system for leaks.