Fuel Tank: Service and Repair

Fuel Pump Connector Location:

Removal
1. Disconnect the fuel pump and fuel gauge connectors.
2. Start and run the engine until it stalls, then turn the ignition switch to OFF.
3. Disconnect the battery negative terminal.
4. Remove the fuel tank cap
5. Drain the fuel.

Caution: Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

6. Disconnect the fuel high pressure line.
7. Disconnect the return line and vapor hose.

Fill And Leveling Hose Connections:

8. Detach the fuel filler hose and leveling hose.






9. Remove the hole cover--see 12 in image--and disconnect electrical connectors.

Fuel Tank Mounts:

10. Loosen the two self-locking nuts, that hold the tank in position.
11. Remove the lateral rods.

Caution: Insure that there is something in position to restrain the tank from falling prior to removing the tank bands.

12. Remove the straps and remove the fuel tank.

Inspection
- Check the hoses and the pipes for crack or damage.
- Check the fuel tank filler tube cap for malfunction.
- Check the fuel tank for deformation, corrosion or crack.
- Check the fuel tank for dust or foreign material.

Note: If the inside of the fuel tank is to be cleaned, use one of the following:
- Kerosene
- Trichloroethylene
- A neutral emulsion type detergent






Installation

Note: When installing the fuel pump and gauge assembly--align the three positioning projections of the packing with the holes in the fuel pump and fuel gauge unit assembly.

1. Install the fuel tank, by tightening the self-locking nuts to the tank bands, until the rear end of the tank band contacts the body.

Fuel Hose Connection Specifications:

2. Connect the leveling hose, from the tank, approximately 1.6 in. (40 mm) onto the filler neck.
3. When connecting the filler hose, the end with the shorter straight pipe should be connected to the tank side.

Vapor Hose Connection Specifications:

4. Connect the vapor hose and return line as shown in the illustration.

High Pressure Hose Connection:

5. Connect the high pressure hose.

Caution: When tightening the flare nut, be careful not to bend or twist the line.

Torque value:
18 - 25 ft lb (25 - 35 Nm)

6. Connect the electrical fuel pump and fuel gauge unit connector.






Notes:
- Before installing the hole cover, apply the specified sealant to the rear floor pan--MOPAR Rope Caulk Sealer 3/16x80" roll Part No.4026044 or equivalent.

- After installing the fuel pump and fuel gauge assembly, start the engine and check to ensure that there is no fuel leakage.

7. Install hole cover.
8. Tighten the drain plug.

Torque value:
11 - 14 ft lb (15 - 20 Nm)

9. Connect the negative battery terminal.