FUEL TANK REMOVAL/INSTALLATION PROCEDURE
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Fuel Tank Filler Assembly
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Fuel Tank Mounting To Frame Rail
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REMOVAL
1. Disconnect battery ground cable.
2. Removal fuel tank filler cap before disconnecting any fuel or vent lines. The tank could be under a small pressure.
3. Pump all fuel from fuel tank into an approved portable holding tank. If this equipment is not available, disconnect the fuel line and drain tank dry into a properly identified "Gasoline" safety container.
4. Raise vehicle on hoist and disconnect all vent hoses and filler hose. Remove the vent hoses from hose routing bracket attacked to the top of the frame rail.
5. Place a suitable jack, centrally, under the fuel tank and apply slight pressure.
6. Remove the nuts from the inboard ends of the two straps and lower tank far enough to allow the fuel tank wires and fuel lines to be disconnected from the unit on top of the tank.
4. Then lower tank further and remove from under vehicle.
WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.
INSTALLATION
1. Place fuel tank on top of jack and raise high enough to connect the fuel line and gauge wire to the gauge unit on top of the tank.
2. Raise tank into position in crossmembers and connect the two end retaining straps. Remove transmission jack. Tighten all straps firmly. Do not over tighten retaining strap nuts. Torque to 35 ft. lbs.
3. Connect vent hoses.
4. Replace drain tube cap.
5. Refill fuel tank and inspect all hoses and lines for leaks. Connect battery cable.
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REMOVAL:
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Fuel Pump Module Removal/Installation
1. Fuel system pressure must be released prior to service.
2. Fuel tank must be removed prior to fuel pump service.
3. While holding the fuel pump module down, remove the retaining clamp. After the clamp is removed release the fuel pump module and it will spring up from the fuel tank.
4. Remove the fuel pump module from the fuel tank.
DISASSEMBLY
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Fuel Gauge Sending Unit Service
1. Remove sending unit attaching screws from mounting bracket located on the side of the fuel pump reservoir.
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Fuel Gauge Sending Unit Wiring Terminals
2. Disconnect electrical connections from sending unit, and remove sending unit.
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Removing Fuel Line Coil From Reservoir
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Fuel Pump And Reservoir Assembly
3. Remove drain tube from the side of the fuel reservoir. Be careful not to let the fuel return line and check valve come detached from the inside of the reservoir.
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Fuel Pump Mount Bracket
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Fuel Pump Removal/Installation
4. Remove the fuel pump assembly by pressing on the mounting bracket with your thumb and forefinger. Press with both thumbs toward the center of the fuel reservoir.
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Servicing In-Tank Fuel Filter
5. Remove pump mounting bracket and rubber collar from hose and retain for assembly. Cut the hose clamp from the supply hose and discard. Remove pump/strainer assembly from hose.
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Servicing In-Tank Fuel Filter
6. If fuel pump is functioning properly but fuel strainer is defective, use a broad blade screwdriver and "walk" around the strainer mounting ferrule to remove it from the fuel pump. Be careful not to damage the fuel pump inlet. If fuel pump is defective, replace both the pump and filter.
ASSEMBLY
1. Press new strainer onto pump (new pumps come with a new strainer).
2. Install new clamp to attach the fuel pump to the supply hose. Use tool # C-4124, or equivalent, to crimp clamp.
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Servicing In-Tank Fuel Filter
3. Reposition pump mounting bracket and rubber collar on the fuel supply hose between the bulge in the hose and the fuel pump.
4. Install the fuel pump inside the fuel reservoir so that the fuel strainer aligns with the cavity in the reservoir.
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Fuel Pump Mount Bracket
5. Snap fuel pump bracket into the reservoir.
6. Install the reservoir so that the drain tube aligns with the mounting lugs on the reservoir.
7. Snap the lower-most fuel coil into mounting lugs in the top of the reservoir.
8. Snap the drain tube into the lugs on the bottom of the reservoir.
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Fuel Gauge Sending Unit Wiring Terminals
9. Connect the electrical wires to the fuel gauge sending unit.
10. Align the index hole on the reservoir with the index tab of the new sending unit mounting bracket.
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Fuel Gauge Sending Unit Service
11. Attach sending unit to mounting bracket and tighten the mounting screws.
INSTALLATION
1. Wipe seal area of tank clean, and install a new O-ring seal on pump.
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Fuel Pump Module Retaining Bracket
2. Align fuel pump module with fuel pump mounting bracket (in the bottom of the fuel tank).
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Fuel Pump Module Removal/Installation
3. Push fuel pump module into the retaining bracket and hold with one hand while tightening the clamp with the other hand. Tighten the clamp to 40 lb-in (4.5 Nm)
4. Install fuel tank assembly.
5. Perform fuel system pressure test to check for leaks.