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 with those on the tank. Install the lock ring and tighten securely.
  4.  
  5. Position the tank on a transmission jack and hoist it into place, feeding the vent hoses through the grommets on the way up.
  6.  
  7. Connect the J-bolts and retaining straps, and tighten to 40 inch lbs. (4.5 Nm). Remove the jack.
  8.  
  9. Connect the filler tube and all vent hoses.
  10.  
  11. Connect the fuel supply line, ground strap, and gauge unit wire lead.
  12.  
  13. Refill the tank and inspect it for leaks. Connect the battery ground cable.
  14.  

Ramcharger

See Figure 5

  1. If there is a tank skid plate, remove it.
  2.  
  3. Disconnect the battery ground cable.
  4.  



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Fig. Fig. 5: Details of the Ramcharger fuel tank mounting

  1. Remove the tank filler cap.
  2.  
  3. Pump or siphon the contents of the tank into a safe container.
  4.  


CAUTION
Siphoning should not be started by mouth! Only fuel-safe pumps should be used.

  1. Raise the vehicle on a hoist and disconnect the fuel line and tank sending unit wire. Remove the ground strap or wire.
  2.  
  3. Remove the hose clamps from the vent dome hose.
  4.  
  5. Remove the filler tube hose clamps. Detach the hoses from the tank.
  6.  
  7. Support the tank with a padded transmission jack.
  8.  
  9. Disconnect the two J-bolts and remove the straps at the rear of the tank.
  10.  
  11. Remove the tank gauge sending unit.
  12.  

To install:
  1. Use a new tank gauge sending unit gasket. Check the filter on the end of the fuel suction tube.
  2.  
  3. Use a new or undamaged tank to frame insulator. Raise the tank into position.
  4.  
  5. Connect the J-bolts and retaining straps. Tighten the bolts until about 1 in. (25mm) of threads protrude.
  6.  
  7. Connect the filler tube and all hoses. Tighten the clamps.
  8.  
  9. Connect the fuel line, ground strap or wire, and tank sending unit wire. Make sure that all fuel line heat shields are in place.
  10.  
  11. Reconnect the battery ground cable and install the skip plate.
  12.  

 
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