Fuel Tank Assembly

Fuel Tank Mounting.:

Fuel System, Exploded View:

Fuel Pump Wiring At Fuel Tank.:

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. Raise the vehicle.
3. Disconnect tank sender unit electrical connector.
4. Disconnect ground lead, if equipped.
5. Disconnect hoses from tank meter assembly.
6. Disconnect hoses at tank from filler and vent pipes.
7. Support fuel tank and disconnect the two fuel tank retaining straps.
8. Remove tank from vehicle.
9. Remove sender unit retainer cam, using tool J 24187, or equivalent.
10. Remove sender unit from tank.

In-tank Electric Fuel Pump.:

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 any insulator pads on top of the tank to reduce rattle and other annoying noises.
4. Tighten the front fuel tank retaining strap bolts to 33 Nm (25 lb.ft.). Tighten the rear strap bolts to 11 Nm (8 lb.ft.).


5. When completed, fill the tank and inspect the entire system for leaks.