Fuel Tank Assembly

Fuel Tank Mounting.:

Exhaust System Removal.:

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. Remove exhaust pipe rubber hangers (2).
4. Remove muffler hanger attaching bolts (2)
5. Remove heat shield attaching screws (3) and heat shield.
6. Remove filler tube and clamp at fuel tank.
7. Remove fuel tank vent tube and clamp at fuel tank vent hose.
8. Disconnect tank sender unit electrical connector.
9. Remove vapor connecting hose from fuel level meter.
10. Remove fuel return quick connect fittings at fuel level meter. Grasp both ends of each fuel line connector and twist 1/4 turn to loosen. Use an air gun to blow out any dirt that may be in the fittings. Squeeze plastic tabs of male end connector of fuel filter, then pull apart.
11. Remove feed quick connect fittings. Insert correct J-37088 tool, or equivalent into female connector, then push inward to release male connector.
12. Plug fuel feed and return connecting lines.
13. Support fuel tank and disconnect the two fuel tank retaining straps.
14. Lower tank enough to disconnect ground lead, if equipped.
15. Remove tank from vehicle.
16. Remove sender unit retainer cam, using tool J-35731, or equivalent.
17. Remove sender unit from tank.

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 any insulator pads on top of the tank to reduce rattle and other annoying noises.

CAUTION: To reduce the risk of fire or injury, always apply a few drops of clean engine oil to the male tube ends before connecting. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O rings in the female connector will swell and may prevent proper reconnection if not lubricated.

4. Tighten the retaining strap bolts to 30 Nm (22 lb.ft.). Tighten the muffler hanger attaching bolt to 15 Nm (11 lb.ft.).


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