Fuel Tank: Service and Repair

REMOVAL

1. Prior to fuel tank removal, fuel should be drained from tank. Disconnect the fuel filler pipe from rubber hose and siphon or pump fuel out though remaining rubber hose.
2. Disconnect fuel hoses and tubes.
3. On vehicles equipped with a metal retainer which fastens the filler pipe to the fuel tank, remove the screw attaching the retainer to the fuel tank flange.
4. Disconnect electrical hookup to the fuel tank sender unit. On some vehicles, the electrical connection is inaccessible on top of the tank and no intermediate connection point is provided. In these cases, the electrical connector must be disconnected from the fuel sender with the tank partially removed from the vehicle.
5. Place a safety support under the tank. Take care not to deform tank to avoid affecting capacity and/or fuel pickup. Remove the bolts or nuts from one end of the fuel tank straps. The straps are hinged at the other end of the way.
6. Partially remove the tank and disconnect the fuel lines and electrical connector from the fuel gauge sender.
7. Remove tank from the vehicle.

INSTALLATION

1. Check the following:
a. Leak check the sender unit.
b. Ensure fuel vapor separator valve is install completely on the tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connection which will be inaccessible after the tank is installed.
d. Replace or install all body mounted fuel tank shields.
2. Place the fuel tank in its proper position in the vehicle. For most models, lubricate the fuel filler pipe with water base tire mounting lubricant. Install the tank onto the filler pipe then bring the tank into final position. Take care not to deform tank to avoid affecting capacity an fuel pickup.
3. Bring fuel tank straps around the tank and start the attaching nut or bolt. Align tank with the straps.
CAUTION: Ensure that fuel tank shields are installed with the straps and are positioned correctly on the tank.
4. Check the hoses and wiring mounted on the tank top to ensure they are correctly routed and will not be pinched between the tank and body.
5. Tighten the fuel tank strap attaching nuts or bolts. Refer to SPECIFICATIONS/MECHANICAL.
6. Reconnect the fuel hoses and lines which are disconnected.
7. Connect electrical connections.
8. Replace fuel drained from the tank.
9. Check all connections for leaks.

FUEL TANK STRAPS

Fuel tank straps can be replaced without removing the tank, by removing one strap at a time, while providing support under fuel tank.
NOTE: Straps may be removed or installed by following procedures above, fuel tank removal and installation.
The hinged end of the strap attachment holds the strap in place after the fuel tank is removed. This hinged end uses a pin type attachment through a loop in the end of the strap.

REMOVAL

1. Push strap up into bracket until pin lines up with large hole. There is a guide and stop inside bracket to assist in aligning strap for removal and installation of pin.
2. Push pin out of large hole in side of bracket by inserting a small drift pin or punch into small hole in opposite side of bracket.
NOTE: A magnetized screwdriver is helpful to draw pin out of large opening in brace if pin does not line up properly.

INSTALLATION

1. Push strap into bracket opening.
2. Insert pin into loop in strap.
3. Pull strap down until pin is fully seated on bottom of bracket.
CAUTION: The pin must rest flat against bottom of bracket. If it does not, fuel tank could be damaged. Do not install tank. Attempt to position pin so that it will seat properly. If unsuccessful, remove pin and strap. Check for, and remove any obstruction that may be inside bracket. Check to ensure pin is correct length.