Fuel Tank Assembly

Pick-up

Fuel Tank Assembly:

Utility

Fuel Tank S/PUP:

CAUTION
Gasoline or gasoline vapors are highly flammable. If an ignition source is present, a fire could occur. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

DRAINING
1. Disconnect negative battery cable (ensure ignition is "OFF").
2. Drain fuel from tank.

REMOVE/DISCONNECT
1. Raise vehicle.

With ZM5 RPO (Shield Package)
2. Shield forward support and bracket. See Image.
3. Supporting shield and tank assembly with proper lowering device, remove remaining bolts holding assembly to frame, lower enough to access hoses and wires on sender and disconnect fuel hoses and sending unit wires.
4. Lower tank and separate from shield. Remove sending unit and purge tank if it is to be repaired. Go to INSTALL/CONNECT.

2. Fuel tank plastic shield.
3. Loosen filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.
4. Support fuel tank and remove fuel tank retaining straps.
5. Lower fuel tank and disconnect fuel/vapor hoses and electrical connections at the sender.
6. Fuel tank from vehicle.
7. Fuel pump/sending unit from tank.
8. Purge fuel tank, if being repaired. Refer to FUEL TANK PURGING.

INSTALL/CONNECT
1. New seal ring and reinstall sender and pump assembly into fuel tank.

NOTE
The strap nuts must be tightened by steps, alternating between the four nuts until the specified torque is reached. Otherwise, the bottom of the tank will flex upward and the fuel gauge will indicate fuel remaining when the tank "runs dry."

With ZM5 RPO (Shield Package)
2. Tank to shield lower.
3. Using appropriate support device raise shield and tank assembly high enough to connect fuel hoses and wire connections for fuel/sending unit and then raise to install lower bolts to frame.
4. Shield forward support and bracket.
5. Go to step 6.

2. Raise tank slightly and reconnect the fuel/vapor hoses and the electrical connections at sender. Ensure the ground strap is also reinstalled to the body.
3. Raise tank fully and reinstall the filler neck to tank. Tighten clamp.
4. Fuel tank brackets with insulator straps in place. Tighten strap nuts to 45 Nm (33 lb.ft.).
5. Fuel tank plastic shield.
6. Replenish fuel. Reinstall fuel tank filler cap.
7. Negative battery cable.
NOTE If a memory retention device was not used, reset (to the extent possible) all devices that lost memory after battery was disconnected).
8. Check for leaks before and after ignition is switched "ON".
9. Lower vehicle.