Removing the fuel tank

Try and run the fuel down as low as possible, (or syphon it out into a safe container).

Get the LeSharo up enough to get underneath it. I ran the front up on ramps and blocked the rears wheels (You must ensure the vehicle is fully supported _anytime_ you are working on it - especially if you are underneath).

I put a small trolly jack under the tank, then undo the hose clamps on the rubber hoses on the fill tube and vent hoses.

Then, with something that will hold a gallon or so of fuel, take the hoses off the fuel pump on the tank side (you will lose some fuel from the hose) put the container under leek to catch gas, then loosen the other hoses.

Then remove the straps that hold up the tank. When lowering the tank the passenger side will come down first because of the hose going to the filler there will be two wires to the sender you will need to remove once its down.

You may need to pry down a little around the edges.

Fuel tank Access (1)

Alternatively, you may try to access the sender unit without removing the tank;

The through the floor method.

We cut a hole in our (1987 gas) LeSharo floor directly above the fuel sender with an air powered nibbler.

The cut has to be made at the front of the tank about 6 inches from the cab line

We were able to work on the sender from that very easily, Several times!

Afterwards, we covered the hole with plywood or whatever.

If you do this be sure to use an AIR-powered nibbler, not a grinder or electrically powered nibbler because of the close proximity to the fuel tank.

If you don't have one have a body shop could do it for you.

Much easier than taking the tank down especially if your first try at fixing the trouble isn't your last one!

I had no problem cutting the hole and removing the sending unit.

USE AN AIR-OPERATED NIBBLER so sparks are not created at the top of the fuel tank which may have petrol vapors or liquid in the area.

DO NOT USE a grinding wheel as shown in the pictures below (the images show the procedure applied to a camper WITH THE FUEL TANK REMOVED).

Bud Stych

Fuel tank access (2)

Fuel Tank Location: Located and accessible from beneath the vehicle.

The tank well is just behind the front seats platform deck floor.

The tank is secured with metal straps, J-bolts, and a sheet metal shield.

The filler access door with filler is located on left side of vehicle just behind the driverŐs door. The filler cap is a vacuum type cap.

Function: The plastic tank stores approx 15.5 gallons of gasoline for the system.

Maintenance The tank must be removed to access fuel filler and vent hoses for replacement. Also removed to access, repair, or replace pump suction hose, return hose from the fuel press regulating valve, vent hose from the charcoal canister to the rollover valve and the quantity (fuel gage) sender.

To gain access to the fuel gage sender and the roll-over valve and hoses going to these items for maintenance or replacement without having to remove the tank, some owners have installed a removable panel over this area.

The removable panel is located thru the floor to the right and slightly behind the driverŐs seat.

This panel can be installed during fuel tank maintenance that requires fuel tank removal. (See illustrations)

The suction line from tank to pump incorporates an in-tank filter mounted on the suction tube to protect the pump.

Do not discard this filter.

Panel, still needs plate fabrication.

Plate secures with 8 screws

Fuel Tank removed, note large (2 inch) fuel filler hose and the ŇspiderÓ mounted on the fuel gauge sender. The vent to filler, the suction, and the relief return tubes are shown. .In the upper left is the roll-over valve. It is connected to the charcoal vapor canister..

(Click images to see larger)