Fuel Tank

Tools Required:

• Fuel Tank Sender Wrench T74P-9275-A
• Rotunda Fuel Storage Tanker 034-00002
• Rotunda Adapter Hose 034-00012

Removal

1. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00012 or equivalent.

   Vehicles with fuel injected engines have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. This situation can be overcome with a few repeated attempts using different hose orientations.

2. Disconnect fuel hoses and tubes.

3. On vehicles equipped with a metal retainer which fastens the filler pipe to the fuel tank, remove the screw attaching the retainer to the fuel tank flange.

4. Disconnect electrical hookup to the fuel tank sender unit. On some vehicles, the electrical connection is inaccessible on top of the tank and no intermediate connection point is provided. In these cases, the electrical connector must be disconnected from the fuel sender with the tank partially removed from the vehicle.

5. Place a safety support under the tank. Take care not to deform tank to avoid affecting capacity and/or fuel pickup. Remove the bolts or nuts from one end of the fuel tank straps. The straps are hinged at the other end and can be swung out of the way.

6. Partially remove the tank and disconnect the fuel lines and electrical connector from the fuel gauge sender, if required. Refer to Push Connect Fitting Removal, if so equipped.

7. Remove tank from the vehicle.
   
   
   
   

Installation

1. Before proceeding, check the following items:
   1. Leak check the sender unit. If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A or equivalent.
   2. Ensure fuel vapor separator valve is installed completely on the tank top.
   3. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the tank is installed.
   4. Replace or install all body mounted fuel tank shields.

2. Place the fuel tank in its proper position in the vehicle. For most models, lubricate the fuel filler pipe with water base tire mounting lubricant. Install the tank onto the filler pipe then bring the tank into final position. Take care not to deform tank to avoid affecting capacity and/or fuel pickup.

3. Bring fuel tank straps around the tank and start the retaining nut or bolt. Align tank with the straps.

    CAUTION: Ensure that fuel tank shields are installed with the straps and are positioned correctly on the tank. Refer to the applicable system illustration.

4. Check the hoses and wiring mounted on the tank top to ensure they are correctly routed and will not be pinched between the tank and body.

5. Tighten the fuel tank strap retaining nuts or bolts to 29-41 Nm (22-30 lb-ft).

6. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel return, (if present) and vapor vent connections are made correctly. Trace the various lines to the engine and refer to the applicable system illustrations to ensure the proper lines are connected.

   Install electric fuel pump as outlined.

7. Connect electrical connections.

8. Replace fuel drained from the tank.

9. Check all connections for leaks.