Fuel Tank Removal/Installation Procedure

FUEL TANK REMOVAL/INSTALLATION PROCEDURE

Fuel Tank Filler Tube And Vent Hose:

Fuel Tank Removal/Installation:

REMOVAL
1. Disconnect battery ground cable.
2. Remove fuel tank filler cap before disconnecting any lines. The tank could be under a small pressure.
3. Pump all fuel from fuel tank into an approved portable holding tank. If this equipment is not available, drain fuel tank dry into a properly identified "Gasoline" safety container. Refer to Draining Fuel Tank in this section.
4. Raise vehicle on hoist.
5. Disconnect fuel, return, and ECS hoses and wire lead to gauge unit, removing ground strap.
6. Remove hose clamps from the hose between the ECS dome and the fuel tank.
7. Remove filler tube hose clamps and disconnect hose from tank.
8. Place transmission jack under center of tank and apply slight pressure. Disconnect the "J" bolts and remove retaining straps and lower tank from under vehicle. Feed the vent hose assembly and filler tube vent hose through the grommets in the frame as the tank is being lowered.

INSTALLATION
1. Position tank on transmission jack under vehicle. Feed hoses and ground wire through grommets while hoisting tank into position. Check hoses for kinking.
2. Tighten "J" Bolts until snug - DO NOT OVER-TIGHTEN. Connect fuel supply, return and ECS hoses. Remove jack.
3. Connect filler tube and all vent hoses, install new hose clamps and tighten securely.
4. ground strap and wire lead to gauge unit.
5. Reconnect battery ground cable.
6. Refill tank and inspect all lines and hoses for leaks, install fuel tank filler cap.