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10-70
FUEL TANK- STATION WAGON
Removal
1. Siphon
the fuel from the fuel
tank into a suitable container.
2. Remove the cargo compartment
mat, spare wheel cover panel and the
spare wheel.
3. Disconnect the fuel gauge send-
ing unit wire at the sending unit.
4. Loosen the hose clamp, slide
the clamp forward and disconnect
the fuel line at the fuel gauge
sending unit.
5. If the fuel gauge sending unit
is
to be
removed,
turn the unit re-
taining ring counterclockwise and
remove the sending unit
retaining.
ring and gasket.
6. Loosen the inlet pipe
to
tank
connecting hose clamps and pull the
hose
clear of
the tank
inlet
pipe.
7. Remove the fuel tank to floor
pan retaining screws and remove the
fuel tank.
Installation
1. Make sure all the old sealer has
been removed from the fuel tank
mounting flange and mounting sur-
face at the floor pan. Apply caulking
cord to the fuel tank mounting
surface at the floor pan.
2. Position the fuel tank to the
floor pan and install the retaining
screws.
3. Position the hose to the fuel
tank inlet pipe and tighten the hose
clamps.
4. If the fuel gauge sending unit
was removed, make sure all the old
gasket material has been removed
from the unit mounting surface on
the fuel tank. Using a new gasket,
position the fuel gauge to the fuel
tank and secure with the retaining
ring.
5. Connect the fuel gauge sending
unit wire to the sending unit.
6. Connect the fuel line at the fuel
gauge sending unit and tighten the
hose clamps securely.
7. Fill the tank and check all
connections for leaks.
8. Replace
the
spare wheel cover
panel and the cargo compartment
mat.
FUEL TANK UTE AND VAN
Removal
1. Siphon the fuel from the fuel
tank into a suitable container.
2. Remove the fuel tank cover set
into the floor of the carrying com-
partment.
3. Disconnect the fuel gauge send-
ing unit wire at the sending unit.
GROUP 10-
FUEL SYSTEM
4. Loosen the hose clamp, slide
the clamp forvard and disconnect
the fuel line at the fuel gauge
sending unit.
5. If the fuel gauge sending unit
is to be removed,
turn
the unit retain-
ing ring counterclockwise and remove
the sending unit retaining ring and
gasket.
6. Loosen the clamps on the fuel
filler pipe rubber hose and remove
the hose from the filler
tank
inlet.
7. Loosen the vent pipe hose
clamp at the tank and move pipe
clear of the tank.
8. Remove
the tank retaining
screws and lift out the tank.
Installation
1. Place the fuel tank in position,
install and tighten the retaining
screws.
_
2. Refit the rubber hose to the
fuel tank inlet and tighten the clamps.
3. If the fuel gauge sending unit
was removed, make sure all the old
gasket material has been removed
from the unit mounting surface on
the fuel
tank.
Using a new gasket, position the
sending unit to the fuel tank and
secure with the retaining ring.
4. Connect the fuel gauge sending
umt wire to the sending unit.
5. Connect the fuel line at the
fuel gauge sending unit and tighten
the clamps securely.
6. Fill the
tank
and check
all
connections for leaks.
7. Replace the fuel tank cover in
the floor of the carrying compartment.
11917-A
FIG. 5-Fuel Line Tube Die
FUEL LINES
The various fuel lines
(Figs.
1, 2, 3
&
4) are not serviced as
a~semblies.
They must be cut, squared and
formed out of rolls of fuel system
service tubing and hose material
available at dealershipf>.
A damaged section of tubing
longer
than 12
inches
can
be cut out
of the existing line and replaced by a
comparable service tubing section,
spliced into the line by means of con-
necting hoses and retaining clamps.
A damaged section of tubing short-
er than
12
inches
can
be cut out of
the line and replaced by a length of
service hose and two retaining
clamps. All replacement hoses
must be cut to a length that will
ensure proper clamp retention
beyond the flared ends of the
connecting tubing.
REMOVAL
1. Drain the fuel from the
tank.
2. Disconnect the line at the fuel
gauge sender unit and the fuel pump.
Remove the lines from the holding
clips along the underbody. Remove
all damaged hose sections and tube
sections.
INSTALLATION
1. Cut a new section of tubing to
approximately the same length as the
section to be replaced. Allow eztra
length for flaring the ends of the
tubing. Square the ends of the cut
tubing with a file.
2. Ream the inside edges of the
cut tubing with the reamer blade on
the tube cutter. Be sure metal
chips are removed from inside
the tube(s). Flare the ends of the
cut tubing, as required, with a stan-
dard tube flaring kit and tool (Fig.
5).
3. Bend the tube section to con-
form to the contour of the original
tube. Cut an ample length of hose
to form a coupling between the flared
ends of the fuel lines. Connect the
hose couplings to the tubing and
install the retaining clamps.
4. Position the lines in the under-
body clips and tighten the clips.
Connect the line to the fuel gauge
sender unit and the fuel pump. Fill
the
tank
and check for leaks.
FILLER PIPE
UTILITY AND
VAN
The utility and van have an upper
filler pipe and hose and a lower filler
pipe and hose. In addition they both
have an external vent pipe between
the fuel tank and the upper ftller pipe.
See Fig. 3.
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