Fuel Tank Assembly

Fuel Tank Insulators:

Fuel Tank Replacement:

Removal

CAUTION:
^ 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.
^ Do Not attempt to repair sections of nylon fuel pipes. If damaged, replace.

NOTICE: If nylon fuel feed or return pipes becomes kinked, and cannot be straightened, they must be replaced.

1. Relieve fuel system pressure (see "Pressure Relief Procedure").
2. Drain fuel tank (see "Fuel Tank Draining").
3. Raise vehicle on hoist
4. Remove filler pipe hose and clamp at fuel tank.
5. Remove fuel tank vent pipe hose and clamp at fuel tank.
6. Disconnect electrical connector.
7. Disconnect vapor connecting hose at fuel sender pipe.
8. Disconnect Quick-connect fittings (see "Servicing Quick-Connect Fittings").
9. Remove exhaust pipe heat shield screws.

NOTICE: Do not bend fuel tank retaining straps, as this may damage straps.

10. With the aid of an assistant, support fuel tank and remove rear fuel tank retaining strap attaching bolts (2) and fuel tank.
^ Place fuel tank in a suitable work area.

Disassembly
1. Remove fuel sender assembly (see "Fuel Pump Replacement").
2. Remove insulator pads from fuel tank and spacers from front fuel tank strap mounting brackets if damaged or new fuel tank is to be installed. Note location pads for installation.

Assembly
1. Install insulator pads on fuel tank and spacers on front fuel tank strap mounting brackets in same location as noted during disassembly.
2. Install fuel sender assembly (see "Fuel Pump Replacement").

Installation
1. With the aid of assistant, position and support fuel tank. Install fuel tank retaining strap rear attaching bolts (2). Tighten rear fuel tank retaining strap bolts (2) to 34 N-m (25 lb. ft.).
2. Install exhaust pipe heat shield screws.
3. Connect Quick-connect fittings (see Servicing Quick-Connect Fittings").
4. Install vapor connecting hose.
5. Reconnect fuel sender electrical connector.
6. Install fuel tank vent pipe hose and clamp.
7. Install filler pipe hose and clamp.
8. Lower vehicle.
9. Add fuel and install fuel filler cap.
10. Reconnect negative battery cable.

Inspection
- Turn ignition switch to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.