Fuel Tank: Service and Repair

FUEL TANK










Removal
1. Drain the fuel into a suitable container at the fuel hose between the fuel pump and fuel tube.
2. Raise the rear of the vehicle.
3. To avoid electrical sparking at the tank, disconnect the ground cable on the vehicle battery.
4. Loosen the clamp on the fuel filler pipe hose at the filler pipe and disconnect the hose from the pipe by pulling along the internal fuel tube from the tank filler neck.
5. Loosen the hose clamps, slide the clamps forward and disconnect the fuel line at the fuel gauge sending unit.
6. Support the tank and remove the lower support bracket bolts or skid plate bolts. Remove the support assembly or skid plate attaching nut at each tank mounting strap. Lower the support assemblies, and lower the tank enough to gain access to the tank vent hose.
7. Disconnect the fuel gauge sending unit wire at the fuel tank.
8. Disconnect the fuel tank vent hose at the top of the tank.
9. Disconnect the fuel tank-to-vapor separator lines at the fuel tank.
10. Remove the fuel tank from under the vehicle.
If the fuel gauge sending unit is to be removed, turn the unit retaining ring. Remove sending unit and gasket.


Installation
1. If the fuel gauge sending unit was removed, make sure all the old gasket material has been removed from the mounting surface on the fuel tank. Using a new gasket, position the fuel gauge sending unit to the fuel tank and secure with the retaining ring.
2. Position the forward edge of the tank and skid plate, if so equipped, to the frame crossmember, support the tank and connect the vent hose to the top of the tank. Connect the fuel tank to vapor separator tank lines at the fuel tank.
3. Connect the fuel gauge sending unit wire to the sending unit.
4. Position the tank, skid plate and straps, and install the attaching parts. Tighten the attaching bolts and nuts to 37-50 N m (27-37 ft-lbs) using thread adhesive (such as "Loctite").
5. Connect the fuel line at the fuel gauge sending unit and tighten the drain plug, is so equipped.
6. Insert the internal fuel tube into the tank filler neck. Connect the filler pipe-to-tank hose and vent tube at the filler pipe-to-tank hose and vent tube at the filler pipe and install the hose clamp. Tighten to 3-4 Nm (25-35 in.lb).
7. Connect the vehicle battery ground cable.
8. Fill the tank and check all connections for leaks.
9. Lower the vehicle.