REMOVAL & INSTALLATION
B Series Pick-up and Navajo
See Figures 1, 2, 3, 4 and 5
- Disconnect the negative battery cable and relieve the fuel system pressure.
- Siphon or pump as much fuel as possible out through the fuel filler pipe.
Fuel injected vehicles have reservoirs inside the fuel tank to maintain fuel near the fuel pick-up during cornering or low-fuel operation. These reservoirs could block siphon hoses or tubes from reaching the bottom of the fuel tank. Repeated attempts, using different hose orientations, can overcome this obstacle.
- Raise and safely support the vehicle.
- If equipped, remove the skid plate attaching bolts, then lower the plate and remove it.
On Navajo models, the front fuel tank strap is bolted to the skid plate and will be disconnected when the plate is removed.
- Disconnect the fuel fill and vent hoses connecting the filler pipe to the tank.
- On vehicles equipped with a metal retainer fastening the filler pipe to the fuel tank, remove the screw holding the retainer to the fuel tank flange.
- Disengage the fuel lines and the electrical connections to the fuel tank sending unit/fuel pump assembly. On some vehicles, these are inaccessible on top of the tank. In this case, they must be disconnected when the tank is partially lowered. To disconnect the lines from the sending unit/fuel pump assembly, refer to "FUEL LINES and FITTINGS" earlier in this section.
- Place a safety support (such as a floor jack) under the fuel tank and remove the bolts from the fuel tank straps. Allow the straps to swing out of the way. Be careful not to deform the fuel tank.
On B Series Pick-up vehicles, the rear fuel tank strap has two connections which must be unbolted.
- Lower the tank a few inches, then detach the fuel lines and electrical connection from the sending unit/fuel pump assembly, if required.
- Remove the tank from the vehicle.
Before installation, it would be wise to perform the following:
- Double-check the tightness of the sending unit/fuel pump locking ring. If it is already loose, now would be a good time to remove it and check the condition of the gasket underneath.
- Ensure that all metal shields are reinstalled in their original positions and that the fasteners are secure.
- Be sure that the fuel vapor valve is completely installed on top of the fuel tank.
- Make all necessary fuel line or wiring connections which will be inaccessible after the fuel tank is installed.
- Raise the fuel tank into position in the vehicle. If necessary, attach the fuel lines and sending unit electrical connector before the tank is in its final position.
- Lubricate the fuel filler pipe with a water-based lubricant. Install the tank onto the filler pipe, then bring the tank into final position. Be careful not to deform the tank.
- Position the tank straps around the tank and start the retaining nut or bolt. Align the tank with the straps. If equipped, be sure the fuel tank shields are installed with the straps and are positioned correctly.
- Check the hoses and wiring on top of the tank. Make sure they are correctly routed and will not be pinched between the tank and body.
- Tighten the fuel tank strap retaining nuts or bolts to 25-34 ft. lbs. (34-46 Nm).
- If not already attached, connect the fuel hoses and lines. Make sure the fuel supply, fuel return (if present) and the vapor vent attachments are made properly. If not already attached, connect the sending unit.
- If removed, install the fuel tank skid plate.
- Lower the vehicle.
- Connect the negative battery cable.
- Fill the tank with fuel and check all connections for leaks.
See Figures 6 and 7
- Relieve the fuel system pressure and disconnect the negative battery cable.
- Remove the fuel filler cap. Raise and safely support the vehicle.
- If equipped, remove the fuel pipe protector and tank under guard.
- Position a suitable container under the fuel tank. Remove the drain plug and drain the tank.
- Disconnect the fuel pump electrical connector.
- Disconnect the fuel lines, evaporative hoses, breather hose and fuel filler hose.
- If equipped, remove the nonreturn valve from the fuel filler pipe and inspect its condition. Replace, if necessary.
- Support the tank with a jack. Remove the retaining bolts and the fuel tank straps.
- Lower the fuel tank from the vehicle.
- Raise the fuel tank into position and install the straps and retaining bolts. Tighten to 32-44 ft. lbs. (44-60 Nm). Remove the jack.
- If equipped, install the nonreturn valve into the fuel filler pipe until the stopper portion of the valve completely fits the pipe.
- Connect the fuel and evaporative hoses, making sure they are pushed onto the fuel tank fittings at least 1 in. (25mm). Connect the breather hose.
- Connect the fuel filler hose, making sure the hose is pushed onto the fuel tank pipe and filler pipe at least 1.4 in. (35mm).
- Connect the fuel pump electrical connector.
- If equipped, install the fuel tank under guard and the fuel pipe protector. Tighten the fuel pipe protector retaining bolts to 14-19 ft. lbs. (19-26 Nm).
- Install the drain plug and lower the vehicle.
- Fill the fuel tank and install the filler cap. Check for leaks.
- Connect the negative battery cable.
- Start the engine and check for leaks.