Chrysler Full-Size Trucks 1989-1996 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



Pick-Ups

See Figures 1, 2, 3 and 4

  1. Disconnect the battery ground cable.
  2.  



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Fig. Fig. 1: Common components of the mid-frame mounted fuel tank

  1. Remove the fuel tank filler cap.
  2.  
  3. Raise the vehicle on a lift. Pump all fuel from the tank into an approved holding tank, and raise the vehicle.
  4.  
  5. Disconnect the fuel line and wire lead to the gauge unit. Remove the ground strap.
  6.  



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Fig. Fig. 2: Common components of the Dakota fuel tank system

  1. Remove the vent hose shield and the hose clamps from the hoses running to the vapor vent tube.
  2.  
  3. Remove the filler tube hose clamps and disconnect the hose from the tank.
  4.  



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Fig. Fig. 3: The fuel tank is mounted to the frame rail as shown-Dakota models

  1. Place a transmission jack under the center of the tank and apply sufficient pressure to support the tank.
  2.  
  3. Disconnect the two J-bolts and remove the retaining straps at the rear of the tank. Lower the tank from the vehicle. Feed the two vent tube hoses and filler tube vent hose through the grommets in the frame as the tank is being lowered. Remove the tank gauge unit.
  4.  



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Fig. Fig. 4: Disconnect the fuel pump module lines when removing the tank

To install:
  1. Inspect the fuel filter, and if it is clogged or damaged, replace it.
  2.  
  3. Insert a new gasket in the recess of the fuel gauge and slide the gauge into the tank. Align the positioning tangs on the gauge w