Frame-Mounted Tank

AFT AXLE FRAME-MOUNTED TANK





Removal
1. Drain the fuel into a suitable container by siphoning through the fuel hose at the fuel pump-to-fuel tube connection.
2. Raise the rear of the vehicle.
3, To avoid electrical sparking at the tank, disconnect the ground cable on the vehicle battery. Then disconnect the fuel gauge sending unit wires at the fuel tank.

4. Loosen the clamps on the fuel filler hose and vent hose at the tank neck. Disconnect the hoses from the tank.
5. Remove the fuel line hairpin clips and disconnect the fuel lines from the fuel gauge sending unit.
6. Support the tank in position.
Remove the nuts and bolts that attach the tank supports to the frame.
Disengage the straps from the front tank support and the rear crossmember.
Lower the tank enough to gain access to the vapor valve.

7. If the vehicle is equipped with carbon canisters, disconnect the vapor hose from the vapor control valve.
8. Lower the fuel tank and remove it from underneath the vehicle.
9. If the fuel gauge sending unit is to be removed from the unit, turn the unit retaining ring counterclockwise and remove the sending unit, retaining ring and gasket.
10. If the vapor control valve is to be removed, pull it out of the grommet located in the top of the tank, and remove the grommet.


Installation
1. If the fuel gauge sending unit was removed, scrape away all the old gasket material from the unit mounting surfaces 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. If the vapor valve was removed, install the grommet in the tank opening and press-fit the valve into place.
3. If the insulation pads were worn or damaged, remove the material and install new pads.

4. Attach the mounting straps to the rear crossmember.
Raise the tank high enough to connect the vapor hose to the vapor valve and connect the hose if applicable.

5. Position the tank assembly against the top straps and install the support and attaching bolts and nuts.
Tighten the nuts to 41 - 56 Nm (30 - 42 ft.lb).

6. Connect the fuel hose(s) to the fuel gauge sending unit.
7. Connect the fuel filler hose to the filler neck and vent hose to the vent neck at the tank.
Tighten the hose clamps to 3 - 4 Nm (25 - 35 in.lb).

8. Connect the vehicle battery ground cable removed in Step 3 of the removal procedure. Connect the fuel gauge sending unit wires.
9. Fill the tank and check all connections for leaks.