Fuel Tank Assembly

Fuel Tank Mounting:

Fuel Tank Wiring:

REMOVE OR DISCONNECT
1. Remove the negative battery cable.
2. Drain fuel tank. Refer to Fuel Tank Draining.
3. Raise vehicle and suitably support.
4. Remove the fuel sender electrical connector.
5. Remove the muffler hanger bolts.
6. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.
7. Remove the hoses from fuel tank sender. Grasp filter and one nylon fuel connection line fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for other nylon fuel connection line fitting.

WARNING: Wear safety glasses when using compressed air because flying dirt particles may cause eye injury.

8. Using compressed air, blow out dirt from quick-connect fittings at end of fuel filter.
9. Remove the quick connect fittings by pulling release tabs back on fuel line quick connector and pulling apart.
10. Remove the hoses at tank from filler, vent and vapor pipes.
11. With aid of an assistant, support fuel tank and disconnect the two fuel tank retaining straps.
12. Remove the tank from vehicle.
13. Remove the sound insulators.

14. Remove the fuel sender assembly from tank.

NOTE: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel line O-Rings for cuts, nicks, swelling or distortion. Replace if necessary.

INSTALL OR CONNECT
1. Install the fuel sender assembly to tank.
2. Install the sound insulators.
3. With aid of an assistant, install the fuel tank to body.
4. Install the fuel tank retaining straps. Tighten the bolts to 35 Nm (26 lb. ft.).

WARNING: In order to Reduce the Risk of Fire and Personal Injury: Before connecting the fuel pipe quick-connect fitting, always apply a few drops of clean engine oil to the male fuel pipe end. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-Rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

5. Install the hoses to filler, vent and vapor pipes.
6. Install the nylon fuel feed and return connecting line quick-connect fittings to fuel sender.
- Apply a few drops of clean engine oil to the male connector tube ends.
- Push connectors together to cause the retaining tabs/fingers to snap into place.
- Once installed, pull on both ends of each connection to make sure they are secure.
7. Install the exhaust rubber hangers.
8. Install the muffler hanger bolts and tighten bolts to 15 Nm (11 lb. ft.).
9. Install the fuel tank sender electrical connector.
10. Lower vehicle.
11. Refill tank.
12. Install the negative battery cable.
13. Check for leaks.
- Turn ignition to ON position for 2 seconds.
- Turn to OFF for 10 seconds.
- Turn the ignition switch to the ON position.
- Check for fuel leaks.