Fuel Tank Assembly

Fuel Tank Components:

WARNING:
- Disconnect the negative (-) battery cables from the batteries.
- Wear safety glasses.
- Siphon or pump fuel into an explosion proof container. Never drain or store diesel fuel in an open container due to the possibility of personal injury from fire or explosion.
- Place "NO SMOKING" signs near work area.
- Have a CO2 fire extinguisher nearby.
- To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

REMOVE OR DISCONNECT
1. Fuel from the tank.
2. Raise vehicle.
3. Loosen clamps from filler neck hose and vent line and disconnect filler neck hose and vent line at tank.
4. Support the fuel tank and remove fuel tank retaining straps.
5. Lower the fuel tank just enough for access to disconnect fuel sender wires, hoses, and ground strap.
6. Lower and remove the fuel tank from the vehicle.
7. Remove the fuel pump/sending unit from the tank.
Refer to FUEL PUMP/FUEL GAUGE SENDING UNIT.
8. Purge fuel tank, if being repaired.
Refer to FUEL TANK PURGING.

INSTALL OR CONNECT
1. Install fuel sender and pump assembly into fuel tank.
2. Install fuel tank into vehicle.
3. Connect sending unit wires, hoses, and ground straps.
4. Install fuel tank retaining straps with anti-squeak strips insulator in place.
- If anti-squeak strips are loose, cement the anti-squeak material securely to the tank with 25 mm (1 inch) wide coverage for 10 cm (4 inches) on each side.
5. Install filler neck hose and vent lines tighten clamps.
6. Install bolts and nuts.
- Tighten strap bolts to 13 Nm (115 in lbs)