Fuel Tank Replacement 15 Gallon Tank

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. If required, raise the vehicle on a suitable hoist. Refer to Lifting and Jacking the Vehicle in General Information.



3. Support the fuel tank shield.
4. Remove the 4 nuts, 2 bolts and fuel tank shield from the frame.

Important: Clean all the fuel pipe and hose connections as well as the surrounding areas before disconnecting the fuel pipes and hoses.

5. Disconnect the vent hose at the fuel tank.
6. Disconnect the filler tube at the fuel tank.



7. Support the fuel tank.
8. With the aid of an assistant, remove the fuel tank strap attaching bolts and the fuel tank straps.
9. Lower the fuel tank enough to disconnect the fuel sender electrical connector and the retaining clips.
10. Disconnect the hoses from the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
11. Remove the fuel tank from the vehicle and place the tank in a suitable work area.
12. If required, remove the fuel sender assembly from the fuel tank . Refer to Fuel Sender Assembly Replacement .

1. Install the fuel sender assembly with new O-rings on the fuel pipes. Refer to Fuel Sender Assembly Replacement .



2. Position and support the fuel tank .
3. Position the fuel tank straps and connect the fuel feed and return hoses to the fuel sender fittings.
4. Connect the electrical connector to the fuel sender assembly.
5. Install the retaining clips.
6. Install the fuel filler vent hose to the vent pipe.
7. Install the fuel filler neck connecting tube to the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.




8. Install the fuel tank strap bolts.

Tighten
Tighten the fuel tank strap bolts to 40 N·m (30 lb ft).

9. Install the fuel tank shield with 4 nuts and 2 bolts.

Tighten
Tighten the fuel tank shield nuts and bolts to 85 N·m (63 lb ft).

10. If required, lower the vehicle.
11. Start the engine and check for leaks.