Katerina Swanson
Removing the fuel tank from a 1991 Dodge Dakota can be a challenging task. While specific steps may vary depending on the vehicle configuration and other factors, some general procedures can be outlined. Before starting, it is essential to ensure the tank is empty and flushed out, and the fuel pump assembly should be handled carefully to avoid issues with the float and sending unit. When it comes to the fuel pump, there are considerations to make regarding the wiring and plug type, as there are differences between the 1991 and earlier models. Additionally, tank straps and the number of people available to assist can impact the approach taken during the removal process.
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What You'll Learn
Prepare by buying tank straps and a premium pump
When preparing to remove the fuel tank on a 91 Dodge Dakota, it is recommended to buy tank straps and a premium pump. This is because the fuel pump in your Dodge Dakota is an essential component that ensures a smooth and controlled flow of gas from the tank to the engine. Over time, the fuel pump may start to whine or make unusual noises, indicating that it needs to be replaced.
You can purchase tank straps for your Dodge Dakota from various retailers, including AutoZone and Advance Auto Parts. These straps are designed to securely hold the fuel tank in place and are constructed to withstand daily and severe road and weather conditions. When replacing the fuel tank, it is recommended to install new tank straps as well. This ensures the safe and secure installation of the fuel tank.
As for the premium pump, it is suggested to opt for a Delphi or Mopar pump instead of an Airtex or Wells unit. Delphi is a renowned manufacturer of dependable fuel pumps and has been in the industry for over 80 years. Their products are known for their innovative designs and high performance.
By purchasing the tank straps and a premium pump in advance, you can ensure that you have the necessary parts on hand when you begin the process of removing and replacing the fuel tank on your 91 Dodge Dakota. This proactive approach can help streamline the repair process and reduce downtime, allowing you to get your vehicle back on the road safely and efficiently.
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Empty the tank, flush, rinse, dry, and clean with isopropyl rubbing alcohol
To empty the tank of your 91' Dodge Dakota, you can use a hose, an air compressor, a manual pump, or simply drain the tank by locating and loosening the drain plug. Using a hose is the most common and straightforward method. Insert the hose into the tank and suck on the other end to start the flow of fuel, then transfer it to a container. Alternatively, an air compressor can be used to force the fuel out of the tank by connecting it to a fuel line and a fuel tank adapter. Similarly, a manual pump can be used to force the fuel out, but it will need to be connected to a fuel tank adapter and a fuel line. If you can locate the drain plug, you can simply loosen it with a wrench and drain the fuel into a container.
Once the tank is empty, you can flush and rinse it with water. It is important to dry the tank very well after rinsing. This can be done by using a hairdryer, a space heater, or an electric leaf blower. You can also use a shop vac to draw air through from the vent hose, but be cautious as static electricity could build up and cause an explosion.
After drying the tank, you can clean it with isopropyl rubbing alcohol (91% if possible). This will ensure that any remaining water is removed from the tank. Isopropyl alcohol has been used to clean fuel tanks and burn up any moisture. It is also recommended to use new gas in the tank after cleaning.
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Disconnect the wires and remove the bed
Disconnecting the wires and removing the bed of a 91 Dodge Dakota can be a challenging task, but with careful planning and execution, it can be accomplished successfully. Here is a step-by-step guide to help you through the process:
Firstly, ensure you have the necessary tools and resources readily available. This includes having a set of tank straps or, alternatively, a spare vehicle to wait for replacement straps if needed. It is also beneficial to have a helping hand, as the bed of the truck can be heavy to lift and manoeuvre.
Locate the wires that need to be disconnected. The wiring diagrams for the 1991 Dodge Dakota may be challenging to interpret due to their complexity and limited clarity. However, it is essential to identify the correct wires to avoid any mishaps. Refer to the wiring diagrams for the 1988 and 1992 models, as they should be similar to the 1990 wiring. Pay close attention to the colour-coding of the wires, as there will be variations. For example, the dark green and black wire is the main power, while the black wire is the ground.
Once you have identified the wires, carefully disconnect them. Use a multimeter on the continuity scale to test the wires and ensure you have identified the correct ones. This step is crucial to ensure you are working with the right connections and to avoid any electrical issues or short circuits.
After disconnecting the wires, proceed to remove the bed of the truck. There are typically eight bolts holding the bed down. Start by undoing all the bolts except for the two on the passenger side. Back out these two bolts just enough so that the bed remains in place but can be lifted and propped up. This will give you enough room to work on the top of the gas tank.
Finally, with the bed lifted and secured, you can now access the fuel tank for repair or replacement. Remember to exercise caution when handling the fuel tank and its components, especially if there is still fuel present. Always refer to professional repair advice and safety guidelines when working with automotive systems.
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Lift the tank out, taking care not to damage the float
To remove the fuel tank from a 91 Dodge Dakota, you will need to carefully lift the tank out, taking extra care not to damage the float. This process can be challenging, so it is recommended to have some helping hands, especially if you are removing a full tank.
Before attempting to lift the tank, ensure that you have followed the necessary steps to prepare for its removal. This includes emptying the tank, flushing and rinsing it with water, and allowing it to dry thoroughly. It is also recommended to chase the cleaning process with some isopropyl rubbing alcohol (91% if available) to effectively remove any residual water.
When you are ready to lift the tank, use a safe and controlled motion to lift it out of its housing. Take special care to avoid damaging the float during this process. The float is a crucial component that can cause issues with the sending unit if it becomes caught or damaged.
Additionally, be cautious of the wiring and fuel lines connected to the tank. You may need to disconnect and label these connections prior to lifting the tank to ensure a smooth and safe removal process.
Once the tank is lifted out, you can proceed with any necessary maintenance or repairs. It is recommended to use new gas and run it out before refilling the tank to avoid having to lift a full tank in the future.
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Reinstall the pump, ensuring the seal or lock nut is secure
When reinstalling the pump, it is important to ensure that the seal or lock nut is secure. This is because the seal or lock nut plays a crucial role in preventing fuel leaks and maintaining the proper functioning of the fuel system.
To ensure that the seal or lock nut is secure, follow these steps:
First, identify the correct seal or lock nut for your 91 Dodge Dakota. The seal or lock nut is a Mopar 4638134, which you can purchase from a dealership or a reputable auto parts store. It is recommended to use a premium pump, such as a Delphi or Mopar, instead of an Airtex/Wells unit.
Next, carefully align the pump with the mounting surface, ensuring that the gasket or sealing surface is clean and free of debris. Make sure the float is not caught on anything, as this can affect the sending unit's operation.
Then, securely tighten the seal or lock nut according to the manufacturer's specifications. Use the appropriate tools and refer to the torque specifications provided by the manufacturer or repair manual to avoid over-tightening.
After tightening, inspect the area for any signs of damage or misalignment. Ensure that all components are properly seated and that there is no debris or residue that could compromise the seal.
Finally, perform a thorough inspection of the fuel system for leaks or other issues. It is recommended to use new gas and run the pump to test its operation. Check for any unusual noises, vibrations, or performance issues.
By following these steps and paying close attention to the seal or lock nut, you can help ensure a secure and reliable installation of the fuel pump in your 91 Dodge Dakota.
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Frequently asked questions
First, empty the tank, flush it out, rinse it out with water, dry it, and then use isopropyl rubbing alcohol to get rid of the water. Then, drop the tank.
Before reinstalling the pump, check the seal or lock nut. You can also refer to a wiring diagram to understand the wires.
The fuel tank in a 91 Dodge Dakota has a capacity of 15 gallons.
It is recommended to use a premium pump, such as a Delphi or Mopar, instead of an Airtex/Wells unit.
Yes, the Gen 1 models should be the same. However, you may need to swap the fuel pump and the wiring to the pump.
