Fuel Tank Replacement

[jimmysgirl]

I have a 89 S15 Jimmy with a major gas leak from the tank. I have decided to try and replace the tank myself. The problem is I have never done this before and don't know where to start.

This might be a longshot, but......Would anyone be able to provide abbreviated instructions for me. Also, how difficult of a task is this? Is there anything I have to be extra careful of?

Thanks,
Alyson

[rlith]

Well, consider the truck is that old, a few things you will need....

Tank (of course)

Get new straps, the old ones may be so corroded you will have to cut them off.

Make sure you get new vents with the new tank

Line wrenches (Not regular box wrenches)

You MAY need a new sending unit depending or not if you can get the old lines off...

Ok, run the gas tank as low as you can (less weight the better)

DISCONNECT THE BATTERY! You don't want any sparks flying should something short when you're dropping the tank!

Jack the back of the truck up from the pumpkin, brace the frame with jack stands and let it down..

Now this really is a 2c man job... Remove the 3 7mm screws at the gas tank filler. Remove the gas tank cover if present. Using a jack and a 2x4 brace the gastank. Now, remove the straps bolts holding the tank to the underbody/frame. If the bolts are too rusted, cover that section of the gas tank with a wet rag and dremmel the but off using a cut off wheel.

Once you get the straps removed, have someone hold the tank as you lower it with the jack. Only lower it 3-4 inches. Now, you will need to maneuver in there with your line wrenches and disconnect the lines from the tank. Disconnect the power harness first.. At this time if the nipples that the lines connect to are corroded, they will snap off if they are bad... (This will determine if you need the new sending unit or not)
Remove any vent hoses attached to the tank.
Once the lines and hoses are off, lower tank all the way, drag out of the way, watch gas spilliage.

For installation, if your sending unit is still intact, using a flathead screwdriver and a hammer, tap the lip of the sending unit counter clockwise until it releases (about an inch or so) Examine the gasket, if it's dry rotted or too flattened, replace it (about 4 bux).

Spray down the sending unit with brake clean and examine all parts to make sure they're moving freely (especially the float). Install the sending unit in the new gastank in the same manner as you removed it.
Remove your old filler neck and any other hoses you left on the tank and install them on the new tank.

Note: The filler neck may be stuck (or seemingly so). Simply take a thin screwdriver and run it completely up the side of the neck all the way around while twisting the hose neck at the same time. It will eventually come off. When putting it on the new tank, use a new clamp..

Reattach all lines and hoses and electrical. Now you can take your old tank with someones help and pour that gas into a gas can and pour that back into the tank, but it's not reccomended due to the amount of debri that will probably be at the bottom of your old tank.

[DINO55]

One more thing, (I hope i'm not to late on this) DON'T SMOKE AT ALL WHILE DOING THIS JOB.

[OverBoardProject]

I couldn't get the bottom straps for my 85, so I had to search my parts trucks and just use the best.

Top straps are available from any parts store.

I forget who I got my tank from, but shop around on the internet.
I think that I saved about $30.00 U.S. on the tank alone.

[rlith]

Originally Posted by DINO55

One more thing, (I hope i'm not to late on this) DON'T SMOKE AT ALL WHILE DOING THIS JOB.

Shhhhhh! Don't give out all our secrets! (j/k)