Fuel Tank: Service and Repair

Fuel Tank Assembly:

Removal

1. Disconnect battery ground cable.
2. Remove fuel tank filler cap before disconnecting any lines. The tank could be under a small pressure.

Portable Holding Tank:

3. Pump all fuel from fuel tank into an approved portable holding tank as shown or equivalent. If this equipment is not available, disconnect fuel line from the inlet side of the fuel pump and connect a siphon hose to it. Drain fuel tank dry into a properly identified "Gasoline" safety container.
4. Remove screws that hold filler tube to body panel or housing.
5. Raise car on hoist.

Fuel Gauge Wiring:

6. Disconnect fuel line, ground wire, gauge wire and wire lead to the tank gauge unit.
7. Place transmission jack under fuel tank. Loosen bolts that hold retaining straps and carefully lower tank until vent line can be removed from roll-over valve located on top of fuel tank. Remove fuel tank from vehicle.

Removing Locking Ring:

Fuel Gauge Unit:

8. Remove gauge unit using a hammer and a nonmetallic drift. Slide gauge unit assembly out of fuel tank. Discard gasket.
9. Remove filler tube.


Installation

Before installing the fuel gauge, check the condition of the filter on the end of the suction tube. If the filter is plugged, install a new one.

1. Insert a new gasket in fuel gauge opening recess then slide gauge into tank. Align the positioning tangs on gauge with those in tank. Install lockring, then tighten securely using a hammer and non metallic punch.
2. Using engine oil as a lubricant, install a new filler tube rubber grommet. Be sure that the inner sealing surface of the grommet is not folded.
3. Locate insulator pad on top of tank. (If tank insulator was torn or damaged during removal of tank, install new insulator).
4. Place tank under vehicle on transmission jack, raise tank to position.
5. Reconnect fuel supply line, ground wire, vent line and wire lead to gauge unit.
6. Carefully raise tank into position with jack and with retaining straps attached install bolts. Tighten bolts to 30 +/- 10 foot-pounds (41 +/- 14 Nm).
7. Lubricate filler tube grommet with engine oil and slide filler tube into tank. Install filler tube mounting screw and tighten.
8. Refill tank and inspect all lines and hoses for leaks.