Fuel Tank Assembly

Fuel Tank Mounting:

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

REMOVAL:

1. Disconnect the negative battery cable.
2. Drain the fuel tank, see MAINTENANCE PROCEDURES/FUEL TANK DRAINING.

Fuel Filler Cap:

3. Remove the fuel tank filler door, seal and drain tube.
4. Disconnect the fuel feed hose, return hose, and vapor hose from the sending unit.
5. Remove the license plate to gain access for removal of 2 carriage bolts securing fascia to the impact bar.
6. Raise the vehicle on a hoist.
7. Remove the spare tire and tire carrier from the frame.
8. Disconnect the intermediate exhaust pipe at the converter.
- Remove the hanger bolt to the intermediate pipe.
- Remove the hanger bolts from the muffler assembly.
- Remove the intermediate pipe and mufflers as an assembly from the vehicle. (Use 2 men)
9. Remove both rear inner fender braces at the frame.
10. Remove both inner fender panels.
11. Remove the antenna ground strap and clip.
12. Remove the rivet securing the fuel vapor pipe to the left hand fuel tank strap.
13. Disconnect the fuel tank cables from the right rear and left rear stabilizer shaft brackets.
14. Remove the 2 screws securing the bottom edge of the fascia to the energy absorber pad.
15. Remove all rear lamps (side marker, tail backup, licence plate and spare tire).
16. Remove the 4 nuts securing each side of the fascia to the horizontal body retainer.
17. Remove the 5 nuts from the right and left vertical retainer securing the fascia to the body.
18. Remove 6 frame bolts, 3 on each side.
19. Loosen 2 front frame bolts, one on each side.
20. With the aid of an assistant, remove the front frame bolts (one on each side). Pull the fuel tank and frame assembly to the rear pushing the cover outward and letting the rear frame assembly down to clear the cover. Remove the vapor hose from the vapor connector and place the tank and frame assembly in a suitable work area.
21. Remove the fuel tank straps and remove the tank.
22. If the fuel tank is being replaced, transfer the cables, fuel meter and pump, and fuel connector to the new tank.

Fuel Tank Cables:

FUEL TANK CABLE REPLACEMENT:

If replacement of the fuel tank cables becomes necessary, the following procedure should be used.
1. Prior to the assembly of the fuel tank on the frame extension, assemble the cables to the fuel tank and cinch securely as shown.
2. Crimp the sleeve with a crimping tool to maintain adequate load to prevent any side or radial movement.

Fuel Tank Insulators:

INSTALLATION:

1. Reverse the removal procedure exactly.
2. Always replace the gasket when the 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 fuel flow. Also, assure that the strainer does not block full travel of the float arm.

3. When installing the fuel tank, be sure to reinstall 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 to the tank or underbody as shown. Apply tape to the front insulator using one 330 mm or two 130 mm pieces of tape.
4. Tighten the front fuel tank retaining strap bolts to 35.0 Nm (26.0 lb.ft). Tighten the rear strap bolts to 11.0 Nm (8 lb.ft).

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

5. Inspect for fuel leaks.