Servicing the Fuel Tank

Before you attempt to remove the fuel tank, it must be empty. It is suggested that you drive your car until the gas gauge is at the "E," or empty, line, and then siphon out the remainder of the gas. Caution: Do not use a droplight when you are working on any of the fuel system components. Spilled gasoline on a hot bulb can cause the bulb to explode and ignite the gasoline. Use a flashlight if it is necessary to illuminate the area where you are working. Never attempt to solder or weld a fuel tank or parts of the car near a fuel tank. Even when a tank is empty of fuel, it may contain enough gas to cause an explosion if the gas comes in contact with a flame or excessive heat.

Removing and replacing the sending unit
Raise and support the front and rear disconnect the negative battery of the car, then open the hood and cable from its post.

1 Disconnect the flexible fuel line
which runs from the fuel tank to the fuel pump and connect the siphon hose to the tank. Siphon the remainder of the gasoline from the tank into a clean five-gallon safety fuel can.

2 Locate the bolts holding the tank strap and liberally spray them with a rust solvent or penetrating oil. While the bolts are soaking, find the vent lines con-nected to the fuel tank. Attach a piece of masking tape to each line, and, using your own code, mark them to insure correct reinstallation. Disconnect the vent lines and the plugged wire connected to the sending unit. This wire is usually mounted on the upper front or top section of the fuel tank.

3 Loosen both bolts holding the fuel tank strap until they are about two threads from the end. Holding the tank firmly against the underbody of the car with one hand, remove the two bolts and slowly lower the tank to the ground. Remove the filler cap and pour the remaining gasoline, if any, into the safety gas can.

4 Remove the sending unit retaining ring with the ring removing tool or take out the screws which hold the sending unit to the tank. Remove the sending unit and gasket from the tank. Note: On some cars the fuel pump and sending units are one component, but the procedure for removal is the same as that described above. Lubricate the sending unit rubber seal with a small amount of petroleum jelly. Then align the locating tangs with the tank opening and install the gasket and sending unit on the fuel tank. Replace the sending unit lock ring or screws and tighten them securely. Lift the tank up under the car's underbody and hold it firmly with one hand while tightening the two tank strap bolts. Connect the vent lines, the fuel line, and the sending unit wires, and hook the fuel line back up to the fuel pump. Pour the siphoned gasoline back into the fuel tank, replace the filler cap, and lower the car. Connect the negative battery cable. Remember, your fuel level is very low, so gas up as soon as possible.