Main Fuel Tank

Figure 3-32: Filler Tube-to-Tank Attachment:

MAIN FUEL TANK

Removal
1. Drain tank with recommended equipment.
2. Remove bolts attaching fuel filler housing to body.
3. Remove vapor canister shield and bracket. Then disconnect tank vent lines, and hoses at branch tee in fuel filler housing.
4. Remove clamps attaching filler tube to vent line or body.
5. Disconnect filler housing ground strap.
6. Loosen clamps securing connecting hose to filler tube and housing (Figure 3-32).
7. Remove fuel filler housing and filler neck.
8. Raise vehicle.
9. Remove rear propeller shaft.
10. Rotate rear axle yoke to a vertical position. Tank may not clear yoke otherwise.
11. Support tank with transmission jack or other suitable support device.

Figure 3-33: Fuel Tank Mounting Strap Attachment:

12. Remove bolts and nuts attaching front and rear upper straps to lower straps (Figure 3-33).
13. Disconnect vent lines at fuel tank.
14. Lower tank enough for access to transmitter wires and fuel lines.
15. Disconnect transmitter wires.
16. Disconnect but do not remove rollover valve line.
17. Lower and remove fuel tank.

Figure 3-34: Fuel Tank and Components:

Fuel Level Transmitter/Pump/Vents/ Access Plate Replacement
The fuel level transmitter, vents, and access plate can all be serviced once the main tank is out of the vehicle (Figure 3-34).

If the fuel tank requires replacement, be sure to replace all necessary gaskets, O-rings, seals, and strainer with new parts. Coat fitting threads with Loctite PST before installation.

Tank Cleaning
In cases where the tank was removed for correction of contamination, remove the transmitter, fuel pump, and access plate for maximum access. Use a soap and water solution and low pressure steam gun. Be sure to clean out the fuel supply and return lines as well. The tank can be dried with compressed air or allowed to air dry as desired.

Main Fuel Tank Installation

NOTE: If tank was replaced, or if transmitter, pump, fitting, or access plate was replaced, verify that components are properly seated and secured.

1. Position tank on jack and raise tank just enough to permit installation of wires and lines.
2. Connect fuel lines as follows:
a. Push lines onto tank supply and return tubes. Note that fuel supply tube is larger in diameter than the return tube.
b. Push line onto tank tube until it snaps or clicks into place.
c. Pull on lines to verify secure attachment.

3. Connect wiring and vent lines. Also connect rollover valve line.
4. Install filler neck-to-tank hose on fuel tank. Secure hose with new clamp if required.
5. Position tank and install bolts and nuts that attach tank upper to lower retaining straps. Tighten strap bolts to 23- 27 lb-in. (3 N.m) torque.

NOTE: If the upper and lower straps touch after bolt tightening, replace the straps. They are stretched or distorted and will not adequately secure the tank.

6. Install propeller shaft.
7. Connect tank vent lines.
8. Lower vehicle.
9. Install filler neck and connect ground strap.
10. Install filler neck housing and connect vent line.
11. Refill tank.
12. Start engine and verify proper operation. Repair any leaks if necessary.