Fuel Tank Assembly

FUEL TANK REPLACEMENT:

Fuel Tank Mounting:

Fuel Tank Wiring:

CAUTION:

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

DO NOT attempt to repair sections of nylon fuel lines. If damaged, replace.

NOTE: If nylon modular fuel sender lines become kinked, and cannot be straightened, they must be replaced.

REMOVE OR DISCONNECT:

1. Negative battery cable.

2. Drain fuel tank.

3. Raise vehicle and suitably support.

4. Fuel sender connector.

5. Muffler hanger bolts.

6. Exhaust rubber hangers. Allow exhaust system to rest on rear axle.

7. Hoses from fuel tank sender. Grasp filter and one nylon fuel connection line fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Using compressed air, blow out dirt from quick-connect fitting, as at end of fuel filter.

8. Quick connect fittings by squeezing plastic tabs of male end connector and pulling apart.

9. Hoses at tank from filler, vent and vapor pipes.

10. With aid of an assistant, support fuel tank and disconnect the two fuel tank retaining straps.

11. Fuel tank from vehicle.

12. Sound insulators.

13. Fuel sender assembly from tank. Refer to "MODULAR FUEL SENDER REPLACEMENT"

INSPECT:

- Inspect connectors for dirt and burrs. Clean or replace components/assemblies as required
- Fuel line O-rings for cuts, nicks, swelling or distorsion. Replace if necessary.

INSTALL OR CONNECT:

1. Fuel sender assembly to tank. Refer to "Modular Fuel Sender"

2. Sound insulators.

3. With aid of an assistant, fuel tank to body.

4. Fuel tank retaining straps.

TIGHTEN:
Bolts to 33 N-m (24 lbs. ft.)

5. Hoses to filler, vent and vapor pipes.

CAUTION: To Reduce the Risk of Fire and Personal Injury:
Before connecting fuel fittings, always apply a few drops of clean engine oil to the male tube ends. This will ensure proper reconnection and prevent a possible fuel leak.

(During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated).

6. Nylon fuel feed and return connecting line quick-connect fittings to fuel sender.

a. Apply a few drops of clean engine oil to the
male connector tube ends.

b. Push connectors together to cause the
retaining tabs/fingers to snap into place.

c. Once installed, pull on both ends of each
connection to make sure they are secure.

7. Exhaust rubber hangers.

8. Muffler hanger bolts.

Tighten:

Bolt to 15 N-m (11 lbs. ft.)

9. Fuel tank sender electrical connector.

10. Lower vehicle.

11. Refill tank.

12. Negative battery cable.

INSPECT:

Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.