Fuel Tank Assembly

Fuel Tank Insulators And Tank Mounting:

WARNING: 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.


REMOVAL:

1. Remove all fuel from the tank, see MAINTENANCE PROCEDURES/FUEL TANK DRAINING.
2. Remove the gas cap.
3. Remove the filler neck shield.
4. Raise the vehicle and remove the rear wheels.
5. Lower vehicle.
6. Remove the Track Bar and Track Bar Brace.
7. Install jackstands and support the axle.
8. Remove the lower shock mount nuts - bolts.
9. Remove the rear exhaust hanger (bolt to pipe only).
10. Remove the exhaust pipe to connector bolts.
11. Remove the brake line cables from the "S" clips (both sides).
12. Remove the brake cable retainer on the right frame rail.
13. Remove the flexible brake cable retainer and package clamp from the left frame rail.
14. Remove the stabilizer bar links.
15. Lower the axle, use care not to damage the flex line.
16. Remove the left and right rear springs.
17. Remove the exhaust system (pipe and muffler).
18. Remove the muffler shield.
19. Remove the exhaust pipe shield.
20. Disconnect the fuel lines and wires.
21. Remove the fuel tank.
22. Remove the fuel pump/sending unit assembly.

Fuel Level Sender Installation:

Fuel Pump/Fuel Gauge Sending Unit (typical):

INSTALLATION:

1. Installation is the reverse of the removal with the following additional steps.
2. Always replace the O-ring gasket when the fuel pump/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. When completed, fill the tank and inspect the entire system for leaks.