Fuel Tank Replacement

Fuel Tank Installed:

REMOVAL
WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye protection, keep open flame away from fuel system components, and prohibit smoking in service areas.
1. Disconnect the battery negative cable.
2. Remove fuel filler cap to relieve pressure.
3. Drain fuel tank.
4. Raise vehicle on a hoist.
5. Remove right rear wheel and splash shield in wheel well.
6. Remove ground wire by filler neck.

Fuel Filler Neck:

7. Disconnect vent hose from filler neck and pull hose out of retaining clip on frame.
8. Remove two nuts holding fuel tank support strap and push strap through left frame rail.
9. Support tank with a suitable jack.
NOTE: Wrap the fuel supply tube and fuel filter lines with a shop towel before disconnecting the quick-connect fittings to absorb any fuel spray.
10. Clean connectors with a clean rag and compressed air before disconnecting to prevent system contamination. Disconnect the quick-connect fittings by squeezing the retainer tabs and pulling the fitting back.
NOTE: The retainer will remain on the nipple.
11. Pull fuel tank to filter supply tube through hole in cross member toward fuel tank.
12. Disconnect pump/sending unit electrical connector. The connector is attached to the frame.
13. Disconnect "Y" shaped tube from the pressure relief/rollover valves at the connecting hose.
14. Remove tank mounting bolts. The fuel tank is now supported only by the jack.
15. Lower the tank two to three inches. Push vent hose through hole in frame toward tank.
NOTE: To remove the tank it will be necessary to tip the rear of the tank down for the mounting flanges to clear the rear axle. Support the tank accordingly so that it does not fall when it is being lowered.
16. Lower the tank.

INSTALLATION
1. Center the tank on a suitable jack under rear of vehicle.
2. Raise on jack until the top of tank is 8 to 10 inches from vehicle.
3. Tilt tank for mounting flanges to clear rear axle and raise tank slowly until it is about two inches away from being in place.
4. Push vent hose through hole in frame, and raise tank into position. Install mounting bolts and torque to 12 lb-ft (16 N-m).
5. Remove jack, install support strap and tighten nut until the distance between the bottom of the strap bolt and the strap is 54-60 mm (2.125-2.362 in.)

Fuel Tank Installed:

6. Install lock nut and tighten
7. Push fuel supply tube through hole in cross member, reconnect fuel lines.
8. Connect electrical connector, connect "Y" hose to evaporator canister tube, attach vent hose to filler neck and replace vent hose in clip on body.
9. Reattach ground wire by filler neck.
10. Install splash shield in wheel well, install rear wheel, lower vehicle, fill tank, install fuel filler cap, and connect negative battery cable.
11. Turn the key to the ON position and check for leaks.