Fuel Tank: Service and Repair

Fuel Lines:

REMOVAL
1. Drain the fuel into a suitable container by siphoning through the fuel line at the reservoir connection.
2. Raise the vehicle.
3. To avoid electrical sparking at the tank, disconnect the ground strap on the vehicle battery. Then disconnect the fuel gauge sending unit wires at the fuel tank.
4. Support the tank in position. Disengage the mounting strap ends attached to the frame side rail. Remove the other end from the tank support by rotating the strap to disengage the "T" shaped hook end.
5. Lower the tank enough to gain access to the vapor valve, fuel filler hose, fuel vent hose, and fuel lines. Loosen the attaching clamps and push connectors, and disconnect the lines. Disconnect the vapor valve hose from the carbon canister tube.
6. Lower the tank and remove it from underneath the vehicle.
7. If the fuel gauge sending unit is to be removed, turn the retaining ring counterclockwise and remove the sending unit, retaining ring and gasket.
8. If the vapor control valve is to be removed, pull it out of the seal located in the tank top and remove the seal.

INSTALLATION
1. If the fuel gauge sending unit was removed, scrape away all the old gasket material from the unit 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. If the vapor valve was removed, install the seal in the tank opening and press fit the valve into place.
3. If the insulation tape was worn or damaged, remove the material and install new pieces approximately 419mm (1 6.5 inches) long, (two pieces).
4. Attach the "T" hook mounting strap ends in the tank supports. Raise the tank high enough and connect the vapor hose to the carbon canister line. Also connect the fuel filler hose, fuel vent hose, and fuel lines. Tighten the clamps that attach the hoses to the mating tank parts.
5. Attach the mounting straps stud end to the frame side rail with attaching nuts and tighten.
6. Connect the vehicle battery ground cable removed in step 3 of the removal procedure. Connect the fuel gauge sending unit wire.
7. Fill the tank and check all connections for leaks.