Fuel Tank Assembly

Fuel Tank Removal

Remove

Fuel Tank Insulators And Tank Mounting:

Fuel Level Sender Installation:

Fuel Pump/Fuel Gauge Sending Unit (typical):

1. Remove all fuel
2. Gas cap
3. Filler neck shield
4. Raise and lower vehicle
5. Right & left rear tires
6. Track bar
7. Track bar brace
8. Install jackstands & support axle
9. Lower shock mount nuts - bolt
10. Exhaust hanger - rear (bolt to pipe only)
11. Exhaust pip to connector bolts
12. Brake line cables from "S" clips (left & right)
13. Brake cable retainer on right frame rail
14. Flexable brake cable retainer & package clamp from left frame rail
15. Stabilizer bar links
16. Lower axle (do not damage flex line)
17. Left & right rear springs
18. Exhaust system (pipe & muffler)
19. Muffler shield
20. Exhaust pipe shield
21. Fuel lines & wires
22. Fuel tank
23. Sending unit with fuel pump (Inc: R & R retainer, O-ring, wiring & tape).

Install

1. Reverse removal procedure.
2. Always replace O-ring gasket when the sending unit has been removed.

NOTE: Care should be taken not to fold over or twist the strainer when installing the sending unit, as this will restrict the fuel flow. Also, assure that the strainer does not block full travel of the float arm.

3. When reinstalling the fuel tank, be sure to install insulator pads on top of the tank to reduce rattle and other annoying noises. Peel off the release paper on the rear insulators and apply them to the tank or underbody as shown. Use one 330 mm or two 130 mm pieces of tape.
4. Tighten the front fuel tank retaining strap bolts to 35 Nm (26 lb.ft). Tighten the rear strap bolts to 11 Nm (8 lb.ft).

NOTE: To keep the tank flange from grounding out against the tank strap bracket, install the left hand strap before the right hand tank strap.

4. Inspect for leaks.