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    1998 Chevrolet Truck Blazer 4WD 4.3L SFI 6cyl

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    Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

    Tank Assembly

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    REMOVAL & INSTALLATION



    Carbureted Models

    This is a general procedure and slight differences may be applicable for your vehicle. Alter the procedure as necessary.

    1. Disconnect the negative battery cable.
    2.  
    3. Detach and label the fuel level gauge sending unit wire.
    4.  
    5. Remove the fuel tank filler cap, then reinstall it.
    6.  
    7. Raise and safely support the vehicle securely on jackstands.
    8.  
    9. Drain the fuel from the tank by removing the drain plug. Be sure to drain the fuel into a container designed for gasoline.
    10.  
    11. Remove the filler hose protector, then detach the filler hose from the tank.
    12.  
    13. Detach the fuel lines and pipes from the fuel tank.
    14.  
    15. Position a floor jack beneath the fuel tank, then remove the fuel tank mounting fasteners. Slowly lower the fuel tank down from the vehicle.
    16.  

    To install:
    1. Position the fuel tank on the floor jack, then slowly raise it up into position beneath the vehicle. Install the mounting fasteners and tighten them until secure.
    2.  
    3. Reattach the fuel lines, pipes and fuel level gauge sending unit wire.
    4.  
    5. Reconnect the fuel filler hose, then install the filler hose protector.
    6.  
    7. Install and tighten the fuel tank drain plug to 22-32 ft. lbs. (30-45 Nm).
    8.  
    9. Connect the negative battery cable.
    10.  
    11. Turn the ignition switch ON without starting the engine, then inspect the fuel tank and associated lines for fuel leaks.
    12.  

    Fuel Injected Models

    See Figures 1, 2, 3 and 4

    This is a general procedure and slight differences may be applicable for your vehicle. Change the procedure as necessary.

    1. Release the fuel system pressure.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the fuel tank filler cap, then reinstall it.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 1: Fuel tank component and fuel line identification for TFI-equipped Samurai models



    Click image to see an enlarged view

    Fig. Fig. 2: Fuel tank component and fuel line identification for fuel injected Sidekick, Tracker and X-90 models



    Click image to see an enlarged view

    Fig. Fig. 3: Fuel tank component and fuel line identification for Sidekick Sport models

    1. Raise and safely support the vehicle securely on jackstands.
    2.  
    3. Detach and label the fuel level gauge sending unit and fuel pump wires.
    4.  
    5. Due to the lack of a drain plug, drain the fuel from the tank through the filler tube with a pump designed for this purpose.
    6.  
    7. Remove the upper filler hose protector, then detach the breather hose from the filler neck and the vapor hose from the separator.
    8.  
    9. Remove the lower filler hose protector, then disconnect the filler hose from the fuel tank.
    10.  
    11. Detacch the fuel filter inlet pipe from the filter.
    12.  
    13. Detach the fuel line and pipe clamps from the chassis, then remove the fuel filter inlet pipe from the clamp.
    14.  
    15. Position a floor jack beneath the fuel tank, then remove the fuel tank mounting fasteners. Slowly lower the fuel tank slightly until the fuel supply and return lines can be disconnected from the fuel tank, then lower the tank completely from the vehicle.
    16.  



    Click image to see an enlarged view

    Fig. Fig. 4: During removal and installation, ensure that all hoses and other connections are properly detached and reattached

    To install:
    1. Position the fuel tank on the floor jack, then slowly raise it up into position beneath the vehicle. Reattach the fuel supply and return lines to the fuel tank, then raise the fuel tank fully. Install the mounting fasteners and tighten them to 36.5 ft. lbs. (50 Nm).
    2.  
    3. Install the fuel filter inlet pipe to the clamp, then reattach the fuel line and pipe clamps to the chassis.
    4.  
    5. Reattach the fuel filter inlet pipe to the filter, ensuring that you use new gaskets. Tighten the fuel filter union bolt to 22-28 ft. lbs. (30-40 Nm).
    6.  
    7. Reattach the filler hose to the fuel tank, then install the lower filler hose protector.
    8.  
    9. Reconnect the breather hose to the filler neck, and the vapor hose to the separator. Install the upper filler hose protector.
    10.  
    11. Reattach the fuel level gauge sending unit and fuel pump wires.
    12.  
    13. Lower the vehicle.
    14.  
    15. Connect the negative battery cable.
    16.  
    17. Turn the ignition switch ON without starting the engine, then inspect the fuel tank and associated lines for fuel leaks.
    18.  

     
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