REMOVAL: Disconnect the negative battery cable.
Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
Drain the fuel tank, refer to MAINTENANCE PROCEDURES/FUEL TANK DRAINING.
WARNING: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.
Raise the vehicle.
Place a transmission jack with a tank adapter under the fuel tank.
Remove the rear tank strap bolts and position the straps away from the tank.
Remove the filler neck and vent hose from the tank.
Slightly lower the tank and disconnect the fuel feed, return, and vent pipes at the O-ring connections.
Remove the tank from the vehicle.
FUEL SENDER/PUMP ASSEMBLY
REMOVAL: Using J 24187 or equivalent Fuel Tank Sending Unit Spanner Wrench, remove the fuel sender assembly retaining cam, fuel sender assembly and O-ring from the tank. Discard the O-ring.
Using a clean shop towel, wipe off the pipe ends.
Inspect all connections for dirt and damage. Clean or replace components/assemblies as required.
Clean all O-ring sealing surfaces.
INSTALLATION: NOTE: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of the float arm.
Install a new O-ring on the fuel tank.
Install the fuel sender assembly in the fuel tank and retainer cam using tool J-24187 or equivalent.
TANK INSTALLATION: Replace the O-rings on the fuel feed and return pipes.
Reposition the fuel tank and reconnect the fuel feed and return pipes.
Connect the filler neck and vent hose to the tank.
Install the rear tank strap bolts.
Reconnect the fuel sending unit connector and clip onto the rear suspension cradle.
Lower the vehicle.
Return the fuel to the tank.
Reconnect the negative battery cable.
Turn the ignition "ON" for two seconds then turn it "OFF" for five seconds. Again turn the ignition switch "ON" and check for fuel leaks.