Fuel Tank - Replacement

CATEGORY
Engine



SECTION
2



PAGE
25



ISSUE
12/92-0293



CODE
234



Supersedes
06/92-0226



Subject:
Replacing the Fuel Tank

Application:
1981 Through 1987 900 Models



The fuel tanks for 900 models, 1981 through 1987, have been superseded by the later model fuel tank, P/N 89 76 425. This part number supersedes the two earlier part numbers, 75 27 542 and 75 34 597. Therefore, if it becomes necessary to replace the fuel tank in one of these cars, you will need to order P/N 89 76 425 and modify the return line to fit the new style tank.



Cars Affected:

All 900 Models from 1981 - 1987 (when changing fuel tank)

Parts:

Fuel Tank 89 76 425
Return Line, Rear 89 76 359
(with Check Valve)
Cap Nut 83 19 238
Nipple 83 19 246

Action:

The fuel tank, P/N 89 76 425, is fitted with a connection bushing for connecting the new return line. Replace the fuel tank as follows:

WARNING

When working with the fuel system, the following safety procedures must be observed. No smoking anywhere in the vicinity. Take care not to cause sparks. Have a suitable fire extinguisher on hand. Work in a well-ventilated area. If approved extraction equipment for fuel vapor is available, use it. Wear suitable gloves, as prolonged contact with fuel can cause dermatitis.





1. When removing the old fuel tank, cut the front return line in front of the check valve. Refer to the arrow in Figure 1.

2. Place the cap nut on the fuel line and install nipple into the end of the fuel line.

3. Install the new fuel tank and connect the rear return line with integral check valve to the tank.

4. Connect the front and rear fuel lines together.

5. After the installation is completed, run the engine and check all connections for leaks.



6. Dispose of old fuel tank.

a. Flush with water.

b. Drill holes in tank to prevent tank from being used for any other purpose. If drilling holes, make sure the tank is filled with water to avoid sparks from igniting gasoline fumes.