Fuel Tank and Fuel Level Sending Unit

Fuel Tank And Mounting Hardware:

TANK REMOVAL:
1. Relieve the fuel system pressure.
2. Disconnect battery ground cable
3. Lift vehicle at least 28" (71cm.)
4. Loosen fuel filler neck connecting tube clamp at the fuel tank.
5. Wrap filler tube connection with a shop towel and carefully remove tube from tank.
6. Use a blunt rod or extension (approx. 18"/46cm length) to push the filler check-ball into the fuel tank.
7. Insert hose w/siphon or other pump through filler neck and pump fuel from tank into an approved container.
8. Remove tailpipe hanger, muffler hanger, and catalytic converter hanger bolts.
9. Remove catalytic converter heat shield, noting position for installation.
10. Support exhaust and move aside for access to fuel tank retaining strap bolts.
11. Remove fuel delivery line at filter and disconnect fuel return line at filter bracket.

NOTE: Be careful not to kink nylon fuel tubes. If any become kinked, they must be replaced.

12. Disconnect fuel sending unit electrical connector.
13. Disconnect vapor and vent hoses at fuel tank.
14. With the help of fan assistant, support fuel tank, remove retaining strap bolts and carefully lower tank from vehicle.

SENDING UNIT REMOVAL
1. Once tank is removed, disconnect fuel and vapor hoses at sending unit.
2. Use sending unit spanner wrench (tool #j-35731), remove retaining cam (locking ring) from top of tank.
3. Remove sending unit/fuel pump assembly from tank. Discard large O-Ring gasket (not for re-use).


INSTALLATION:
1. Using a new O-ring, replace the fuel sending unit.
2. Insert check ball into fuel tank filler neck and "POP" into place.
3. Raise the fuel tank into position enough to connect the sending unit, hoses, and ground strap if equipped.
4. Install the fuel tank retaining straps and tighten the bolts.
5. Install remaining parts in the opposite order of removal.
6. Refill the tank with fuel and check for leaks.