Fuel Tank: Service and Repair

WARNING: Before disconnecting any fuel line, release fuel pressure with the following procedure. When replacing fuel system components, keep sparks, cigarettes and open flames away from fuel. Use a rag as protection from spray when disconnecting hoses. Plug hoses while they are disconnected. Before repairing fuel tank, clean thoroughly with steam to remove all explosive gas.

Fuel Tank R&R:

1. Disconnect negative battery cable.
2. Drain fuel from tank and store in an approved container.
3. Disconnect hoses and electrical connectors from top of tank.
4. Raise vehicle on hoist or jack up vehicle and support with safety stands.
5. Remove main silencer (muffler).

CAUTION: To avoid damaging crankshaft position sensor mounted on rear of cylinder head, do not move transmission more than necessary when removing and replacing power plant frame (PPF).

PPL Frame Bracket:

6. Disconnect wire harness from power plant frame.
7. Support transmission with a jack.
8. Remove PPF frame bracket.

PPL Differential Bolt Spacer:

9. Remove differential-to-PPF bolts and pry spacer from front bolt hole.

PPL Differential Mounting Spacer:

10. Unbolt and remove differential mounting spacer.

PPF Mounting Sleeve:

11. Turn a bolt (M14 X 1.5) into sleeve as shown on image.
12. Twist and pull bolt downward.
13. Install a second bolt (M6 X 1) into hole in side of differential carrier to hold sleeve in place. Remove long bolt (M14 X 1.5) and then remove second bolt (M6 X 1).
14. Remove PPF mounting bolts from transmission end and remove PPF from vehicle.

PPF Spacer Caution:

CAUTION: Do not remove spacers show in image from PPF. If they are removed, replace PPF as an assembly.

15. Loosen clamp at fuel filler hose connection to tank. Pull hose free from filler pipe on tank.

Fuel Filter:

16. Remove fuel filter cover and filter mounting bolts. Move filter aside without disconnecting fuel hoses.

Brake Pipe Joint Removal:

17. Remove brake pipe joint nuts and move aside with brake pipe and brake hose still connected.
18. Unbolt battery cable clamp.

Rear Crossmember Removal:

19. Support rear crossmember with an appropriate jack and remove mounting nuts and bolts. Lower crossmember assembly.
20. Remove bolts securing tank to vehicle and remove tank toward rear of vehicle. If not previously done, remove evaporation hoses from connections on top of tank.
21. Reinstall tank in reverse order and observe the following:
a. Ensure that fuel and evaporation hoses are pushed onto their fitting at least 1 inch (25 mm).
b. Push fuel filler hose onto tank filler pipe at least 1.4 inches (35 mm).

22. Install differential mounting spacer for PPF and torque bolts to 27 - 38 ft lb (37 - 52 Nm).
23. Ensure that transmission is supported in a level position.
24. Position PPF in place and tighten transmission end mounting bolts by hand.

PPF Reamer Bolt:

25. Install PPF differential mounting bolts and tighten by hand. Ensure that reamer bolt and spacer are placed in front hole and that sleeve in front hole is properly positioned.
26. Install PPF frame bracket and tighten bolts by hand.
27. After all bolts are in place, torque as follows:
a. Differential mounting bolts: 77 - 91 ft lb (104 - 123 Nm).
b. Transmission mounting bolts: 77 - 91 ft lb (104 - 123 Nm).

PPF Frame Bracket Torque:

28. Torque PPF bracket bolts identified in the image as "B" to 27 - 40 ft lb (36 - 54 Nm). Bolt labeled "A" is a previously tightened transmission mounting bolt.