Fuel Tank, Removing and Installing
WARNING: FIRE HAZARD! Disconnect battery ground strap when working on the fuel system. Do not smoke or create any sparks where odor of fuel vapor is present.Fuel Pump Lines:
NOTE: Be prepared! Removing the fuel tank requires removal of the rear differential. Several jacks are necessary to do this. It is recommended that a vehicle hoist and transmission jack be used as well as an assistant to help lower the differential from the car.
Fuel Pump Access Plate:
1. Relieve fuel system pressure.
^ Open luggage compartment and remove floor covering.
^ Remove access panel for fuel pump and disconnect fuel tank electrical connector.
^ START engine and let run until it dies, this will relieve any pressure that may remain in the fuel lines.
^ Reconnect fuel tank electrical connector.
Fuel Pump Relay Location:
2. Drain fuel tank.
^ Connect an additional piece of hose to the fuel supply line at the fuel rail and direct the open end into a suitable clean storage container. Be sure container is large enough to hold all the fuel in the tank.
^ Remove fuel pump relay (located in the Central Electric Panel, under the left side dash) and energize fuel pump by connecting jumper wire between relay socket terminals 32/30 and 30/87F.
^ Run pump until tank is empty.
NOTE: If fuel pump will not operate, use a siphon pump and hose to drain the tank.
Fuel Pump Lines:
3. Inside trunk, disconnect fuel and vapor hoses.
4. Remove both rear wheels and right wheel well liner.
Overflow Line, Clip, And Grommet:
5. Unclip overflow line (upper arrow) and pull out of rubber grommet (lower arrow). Do not remove overflow line from filler neck.
Filler Tufbe Hose And Clamp:
6. Loosen clamp (arrow) and separate filler tube from fuel tank hose.
Removing Splash Shield And Filler Tube:
7. Remove fastening screw (arrow) pry retaining ring out of splash shield using screwdriver, pull out filler tube.
Exhaust Pipe Coupling:
8. Disconnect exhaust system (arrows) WITHOUT removing down pipe and catalytic converters.
Heat Shield (Above Exhaust Pipe Coupling):
9. Remove nuts from heat shield at exhaust system separation point.
Heat Shield (Rear Of Cross Member):
10. Remove heat shield bracket I.
Heat Shield (Front Of Cross Member):
11. Remove nuts from heat shield panel in front of bracket I.
Heat Shield (Under Fuel Tank):
12. Remove fuel tank heat shield.
13. Push parking brake out of guides at cross member.
Exhaust Supports:
14. Remove exhaust system supports.
Disconnecting Drive Shaft:
15. Remove driveshaft flange bolts, disconnect driveshaft and tie off to one side.
Left Axle Cover:
16. Remove cover panel bolts for left drive axle.
Drive Axle Flange And Bolts:
17. Remove bolts from drive axle flanges (both sides), disconnect drive axles and tie out of the way.
Left Parking Brake Cable Bracket:
18. Remove bolt for left parking brake cable bracket on differential.
Right Parking Brake Cable Bracket:
19. Remove bolt for right parking brake cable bracket on differential.
Removing Parking Brake Cable From Caliper:
20. Disconnect parking brake cables from calipers and pull cables through holes in cross-member as far as possible. Be careful not to damage plastic sheathing.
Brake Fluid Lines And Junction Block:
21. Disconnect left and right brake lines (arrow A).
22. Disconnect brake line (arrow B) from distribution block.
Differential Mounting Nut Location:
23. Remove differential mounting nut.
Supporting Rear Crossmember:
24. Support rear differential cross-member with a jack.
Crossmember Mounts:
25. On vehicles with an auxiliary heater, remove cross-member nuts as shown in illustration.
Return Valve Bracket:
26. Remove bolt for return valve bracket.
Crossmember (I), Support Bracket (II), And Mounting Bolts:
27. Loosen bolt A and remove bolt B and carfully lower bracket I to the front.
Partially Lowered Differential And Crossmember:
28. Support differential with jack, fasten differential to jack with belt or strap if possible.
Support Bracket And Mounting Bolts:
29. Detach bracket II from bracket I by removing nuts at arrows.
30. Remove differential from rear cross member and lower carefully.
Fuel Tank Fastener Locations:
31. Remove fuel tank retaining nuts and lower tank from vehicle.
32. Installation is the reverse of removal. If new tank is installed, secure sound insulator strips in same locations as on the old tank.
Hose Retainers And Clamps:
NOTE: When installing fuel tank, be sure to secure fuel hose with clamp B, and vapor hose with adhesive strips A as shown in illustration. When fuel tank installation is complete, bleed the air from the brake system and adjust the parking brake.
Replace all self locking nuts or secure with thread locking compound. Tighten nuts and bolts to the following torque specifications.
DRIVE SHAFT TO DIFFERENTIAL 55 Nm (41 ft.lbs)
DRIVE AXLES TO DIFFERENTIAL 80 Nm (59 ft.lbs)
REAR CROSS-MEMBER TO BODY 50 Nm (37 ft.lbs)
CONTROL ARM BUSHING TO REAR CROSS-MEMBER 85 Nm (63 ft.lbs)
FRONT BRACKET TO DIFFERENTIAL 45 Nm (33 ft.lbs)
REAR DIFFERENTIAL BUSHING TO CROSS-MEMBER 45 Nm (33 ft.lbs)
EXHAUST BRACKET TO CROSS-MEMBER 55 Nm (41 ft.lbs)
M8 BOLTS 45 Nm (33 ft.lbs)
M10 BOLTS 80 Nm (59 ft.lbs)