Fuel Tank: Service and Repair

Removal and Installation

NOTE: Make sure fuel tank is properly supported during removal and installation procedures.

1. Drain fuel from fuel tank. This can be done by disconnecting the fuel tank filler pipe from the tank filler neck.

2. Support fuel tank, then remove the 10mm fasteners at the front fuel tank support.

3. Loosen the fuel tank support strap (making sure tank is supported) and remove.

4. Lower the fuel tank then disconnect the fuel lines from sender tubes and electrical connector. Remove the vapor valve hose. Remove the remaining fuel filler vent pipe.

5. For installation, follow removal procedure in reverse order.

- Tighten front support bolts to 34-46 Nm (25-34 lb.ft.).

- Install fuel tank support strap and tighten bolt to34-46 Nm (25-34 lb.ft.).

NOTE:Refer to illustration for proper installation of fuel tank filler pipe making sure horseshoe clip is engaged.

Plastic Midship, Ranger

Removal and Installation

NOTE: Make sure fuel tank is properly supported during removal and installation procedures.

1. Drain fuel from fuel tank.

2. Loosen fill pipe clamp.

3. (4x4 only) Remove bolts securing skid plate assembly to frame and remove assembly from vehicle.

4. Remove fuel tank filler pipe from vehicle.

5. Support fuel tank.

6. Remove bolts and nuts from rear fuel tank support strap and remove rear fuel tank support strap.

7. Remove bolt and nut from front fuel tank support strap and remove front fuel tank support strap.

8. Lower fuel tank.

9. Remove fuel supply hose at sender push connector. To disconnect push connect fittings: Fuel Line Coupler

10. Remove fuel return hose at sender unit push connector. To disconnect push connect fittings: Fuel Line Coupler

11. Disconnect sender and fuel pump electrical connector.

12. Remove fuel vapor hose from evaporative emission valve.

13. Lower fuel tank from vehicle.

14. For installation, follow removal procedures in reverse order. The fittings used on 7.9mm (5/16-inch) nominal diameter nylon tubing use a hairpin clip.

NOTE: Clips should be replaced whenever a connector is removed.

Tighten U-lock nuts securing front and rear fuel tank support straps to 34-46 Nm (25-34 lb ft).
Tighten clamp securing fuel tank filler pipe to 3-4 Nm (27-35 lb in).