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Fuel Tank Installation

Last Updated: Dec 28, 2016 01:39PM EST
CAUTION Fuel is highly flammable. Work in a well-ventilated area away from sparks and open flames. To eliminate the risk of fire and personal injury, depressurize the fuel delivery system before attempting any service. Make sure you have a class B fire extinguisher close by. Dispose of fuel in a recommended and secure container.

REMOVAL • Depressurize fuel system as recommended by the manufacturer. • Disconnect the battery or fuel delivery related fuses as per manufacturer’s recommendations. • Remove fuel filler cap and empty fuel tank in a recommended container. (Note: Some filler necks or fuel tanks are equipped with a rollover safety valve. Tank may not be emptied by the filler neck unless removed) • Disconnect all fuel and vapor lines. • Disconnect and inspect all electrical connectors including grounds. • Disconnect and inspect fuel filler neck (if necessary) • Support fuel tank. • Loosen and remove fuel tank holding straps. Replace straps if damaged or severely rusted. • Carefully lower fuel tank. • Recuperate all rubbers and insulators that are found between the floor and fuel tank. Note: A damaged or corroded filler neck may be the cause of tank contamination

INSTALLATION • Read carefully all instructions found in the packaging. • Install all necessary parts. • Replace wiring harness if applicable (included with the tank assembly) • Strap fuel tank back on (ensure all rubber insulators are in place to prevent noise) • Reconnect filler neck, fuel and vapor hoses (ensure condition of seals and clamps) • Reconnect electrical connectors and ground (ensure cleanliness) • Install new fuel filter. • Add clean or filtered fuel back in the fuel tank (never dry run a fuel pump) • Reconnect battery or related fuses. • Cycle the key ON several times without starting the engine with intervals of 10 sec. between cycles. This will pre-charge and pressurize the fuel system. • Start the engine and check and correct any fuel delivery system leaks. • Reconnect fuel pressure gauge and verify with manufacturers specifications. • Road test vehicle

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