Fuel Tank Assembly

FUEL TANK REPLACEMENT

Removal

Fuel Tank Insulators And Tank Mounting:

Fuel Level Sender Installation:

Fuel Pump/Fuel Gauge Sending Unit (typical):

CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

1. Relieve fuel system pressure.
2. Fuel filler neck shield and attaching screws.
3. Drain fuel tank.
4. Raise vehicle on hoist.
5. Rear axle assembly.
6. Exhaust system.
7. Muffler heat shield and attaching screws.

Clean: Clean all fuel pipe and hose connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.

8. Rear fuel feed pipe assembly from fuel level meter assembly.
9. Fuel return, vapor, and vent hoses and clamps at fuel level meter assembly.
10. Electrical connector.

NOTICE: Do not bend fuel tank straps, as this may damage straps.

11. With aid of an assistant, support fuel tank, and remove fuel tank strap front attaching bolts, fuel tank straps and fuel tank.
- Fuel tank from vehicle and place in a suitable work area.

Install

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

1. With the aid of assistant, position and support fuel tank. Position fuel tank straps, loosely install front fuel tank strap attaching bolts and rear fuel tank attaching strap bolts and nuts.

Tighten
Front fuel tank strap attaching bolts to 34 N.m (25 lb. ft.).

2. Electrical connector.
3. Fuel return, vapor, and vent hoses and clamps at fuel level meter assembly.
4. Rear fuel feed pipe assembly from fuel level meter assembly.

Tighten
^ Use back-up wrench to prevent filter from turning.
^ Rear fuel feed and return pipe assembly fittings to 27 N.m (20 lb. ft.).

5. Muffler heat shield and attaching screws.
6. Exhaust system (pipe & muffler).
7. Rear axle assembly.
8. Lower vehicle.
9. Fuel filler neck shield and attaching screws.
10. Add fuel and install fuel filler cap.
11. Negative battery terminal.