Chrysler RAM50/D50/Arrow 1979-1993 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figure 1


CAUTION
Gasoline in either liquid or vapor form is EXTREMELY explosive. An empty tank can sometimes be more hazardous than a full one due to vapor accumulation. Observe no smoking/no open flame rules during this procedure. Take extreme care to avoid sparks from any source, including electric switches and dropped tools. Have a dry powder (type B-C) fire extinguisher within arm's reach at all times and know how to use it. Always store drained fuel in metal containers with an airtight lid. Liquid gasoline may cause skin irritation or allergic reaction; avoid splashing fuel on clothing.

Common sense dictates that the tank be very close to empty before draining it. Have a funnel and a supply of rags on hand before beginning.



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Fig. Fig. 1: On all models, make certain that the fuel return line is properly connected (upper) and that the check valve (arrow) is not upside down

1979-82 Models See Figure 2


WARNING
Be sure the ignition switch is in the OFF position.

  1. Remove the fuel filler cap to release any pressure in the tank.
  2.  
  3. Elevate and safely support the vehicle on jackstands.
  4.  
  5. Remove the drain plug from the fuel tank.
  6.  
  7. Disconnect the fuel hoses from the tank.
  8.  
  9. Support the tank with a jack, remove the retaining nuts and remove the tank.
  10.  
  11. Remove the separator tanks from the tank.
  12.  
  13. Connect the hoses and the filler neck to the body.
  14.  
  15. Apply a small amount of sealant to both sides of the packing when replacing the gauge unit.
  16.  
  17. Installation is the reverse to removal procedure.
  18.  

1983-90 Models See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Elevate and safely support the vehicle on jackstands. For 1986-89 models, remove the small side skirt panel on the left side.
  4.  
  5. Remove the filler cap to equalize pressure within the tank.
  6.  
  7. Remove the drain plug and in-tank filter. Drain the fuel into a suitable metal container with an airtight lid. Later models may not have the in-tank filter.
  8.  
  9. Loosen the fuel hose clamps (main, return and vapor) at the fuel tank and disconnect the hoses. Label or identify each hose and port.
  10.  
  11. Remove the electrical harness from the fuel gauge unit.
  12.  
  13. Remove the filler neck retaining bolts from the body. Remove the filler hose protector.
  14.  
  15. Use a floor jack and a broad piece of wood positioned under the fuel tank to support the tank.
  16.  
  17. Remove the tank mounting nuts.
  18.  
  19. Lower the tank to the ground.
  20.  
  21. Install the new tank by raising it into place with the jack.
  22.  
  23. Install the retaining nuts and tighten them to 32 Nm (24 ft. lbs.). When the tank is secure, the jack may be removed.
  24.  
  25. Connect the electrical harness to the gauge unit.
  26.  
  27. Install the filler hose protector and install the neck-to-body retaining screws.
  28.  
  29. Install the hoses to their ports, making certain that each clamp is secure.
  30.  
  31. If not already done, install the in-tank filter and drain bolt. Tighten the bolt to 44 ft. lbs. (59 Nm).
  32.  
  33. Using a funnel, carefully refill the tank with the drained fuel. Avoid splashing fuel onto the painted bodywork. Install the filler cap.
  34.  
  35. Lower the vehicle to the ground and connect the negative battery cable.
  36.  
  37. Start the engine. It will take a period of cranking before the engine fires and runs smoothly due to the lines being emptied.
  38.  
  39. Check the entire work area carefully for any sign of leakage. A small leak will not drip but will only show up a slight moisture on the hose. Attend to all leaks immediately.
  40.  

1991-93 Models See Figures 4 and 5

Although some slight differences may appear between different model years or makes, the procedures for all 1991-93 Dodge trucks is essentially the same. Refer to the illustrations if any discrepancies arise.

  1. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 2: Fuel tank assembly and component location-1979-82 models

  1. Unplug all wiring harnesses from the fuel tank (fuel pump and fuel gauge unit connectors).
  2.  
  3. Elevate and safely support the vehicle on jackstands.
  4.  
  5. Remove the filler cap to equalize pressure within the tank.
  6.  
  7. Remove the drain plug and drain the fuel into a clean, suitably-sized container with a sealable top.
  8.  
  9. Remove the side skirt panel stay.
  10.  
  11. Remove the main hose, return hose, vapor hose, breather hose and fuel filler hose connections.
  12.  
  13. On vehicles equipped with a 3.0L engine, remove the fuel tank protector.
  14.  
  15. Position a floor jack under the fuel tank and support the tank with it.
  16.  
  17. Remove the fuel tank mounting nuts and lower the fuel tank with the floor jack.
  18.  
  19. At this time, the fuel tank pressure relief valve, fuel pump assembly, or fuel gauge sending unit can be removed from the fuel tank.
  20.  

To install
  1. Lift the fuel tank back up into its position with the floor jack.
  2.  
  3. Secure the tank in place with the fuel tank mounting nuts. Tighten them to 18-22 ft. lbs. (25-30 Nm).
  4.  
  5. Install the fuel tank protector plate, if so equipped.
  6.  
  7. Install the fuel filler hose until its end contacts the fuel tank.
  8.  
  9. Install the breather and return hoses to the nipples, making sure that they are pushed at the least 1-1.20 in. (25-30mm) on.
  10.  
  11. Reattach the vapor hose connection.
  12.  
  13. Install the main hose. Temporarily tighten the flare nut by hand, then tighten it to 22-29 ft. lbs. (30-40 Nm), being careful that the fuel hose does not become twisted.
  14.  


CAUTION
When tightening the flare nut, be careful not to bend or twist the line, which could cause damage to the fuel tank connection.

  1. Attach the fuel pump and the fuel gauge unit connectors.
  2.  
  3. Install the side skirt panel stay.
  4.  
  5. Fill the tank with approximately 1 gallon of gasoline and connect the negative battery cable.
  6.  
  7. Start the engine and check for any fuel leaks around the hoses going to the fuel tank and their connections; repair if necessary.
  8.  



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Fig. Fig. 3: Fuel tank assembly and component location-1983-90 models



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Fig. Fig. 4: Fuel tank assembly and component location 2.4L engine



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Fig. Fig. 5: Fuel tank assembly and component location 3.0L engine

 
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