Fuel Tank Assembly

Exhaust/Heat Shield Removal:

Fuel Tank Replacement:

WARNING: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

REMOVAL
1. Relieve the fuel system pressure, refer to DIAGNOSIS ,TESTING AND INSPECTION PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2. Drain the fuel tank, refer to DIAGNOSIS, TESTING AND INSPECTION PROCEDURES/DRAINING FUEL TANK.
3. Raise the vehicle on a hoist.
4. Remove the exhaust pipe hangers.
5. Remove the muffler hanger attaching bolts.
6. Remove the heat shield attaching screws and heat shield.
7. Disconnect the filler tube and clamp at the fuel tank.
8. Disconnect the fuel tank vent tube and clamp at the fuel tank vent hose.
9. Disconnect the electrical connector.
10. Disconnect the vapor connecting hose from the fuel level meter.

CAUTION: If the nylon fuel feed or return connecting lines become kinked, and cannot be straightened, they must be replaced.

11. Grasp the fuel level meter fuel feed tube and nylon fuel feed connecting line quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within the quick-connect fitting. Repeat for the nylon fuel return connecting line quick-connect fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

- Using compressed air, blow the dirt out from the quick-connect fittings.
12. To disconnect the fuel return quick-connect fittings:
- Squeeze the plastic tabs of the male end connector and pull the connection apart.
13. To disconnect the fuel feed line quick-connect fittings:
a. Choose the correct tool from the J 37088-A tool set for the size of the fitting.
b. Insert the tool into the female connector, then push inward to release the male connector.
14. Plug the nylon fuel feed and return lines.

CAUTION: DO NOT bend the fuel tank retaining straps, as this may damage the straps.

15. With the aid of an assistant, support the fuel tank and remove the fuel tank retaining strap attaching bolts, fuel tank, and both fuel tank retaining straps.
- Place the fuel tank in a suitable work area.

NOTE: If it is necessary to remove rust or burrs from the fuel level meter tubes: use emery cloth in a radial motion with the tube end to prevent damage to the O-ring surface.

- Using a clean shop towel, wipe off the male tube ends.
- Inspect all tube ends for dirt and burrs. Clean or replace components/assemblies as required.
- Inspect fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.
16. Remove the fuel pump/level meter assembly. Service and Repair
17. Remove the insulator pads, noting the location of the pads for installation.
18. Remove the heat shield attaching clip, heat shield, and heat shield insulation.

INSTALLATION
1. Assemble the fuel tank heat shield insulation, heat shield and attaching clip.
2. Install the insulator pads in the same location as noted during disassembly.
3. Install the fuel pump/level meter assembly.
4. With the aid of an assistant, position and support the fuel tank. Install the fuel tank retaining straps, and attaching bolts. Tighten the retaining strap bolts to 30.0 N-m (22.0 lb. ft).
5. Unplug the nylon fuel feed and return connecting lines.

WARNING: To reduce the risk of fire and personal injury: Before connecting the fuel lines, always apply a few drops of clean engine oil to the male tube ends. This will assure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated).

6. To connect the nylon fuel feed and return connecting line quick-connect fittings to the fuel pump/level meter:
a. Apply a few drops of clean engine oil to the male connector tube ends.
b. Push the connector together to cause the retaining tabs/fingers to snap into place.
c. Once installed, pull on both ends of each connection to make sure the connection is secure.
d. Repeat for the other fitting.
7. Reconnect the vapor connecting hose.
8. Connect the electrical connector.
9. Install the fuel tank vent hose and clamp.
10. Connect the filler tube and clamp.
11. Install heat shield and attaching screws.
12. Add fuel and install fuel filler cap.
13. Connect the negative battery cable.
14. Turn the ignition switch to the "ON" position for two seconds, then turn it to the "OFF" position for ten seconds. Again turn the ignition to the "ON" position and check for fuel leaks.

Tools required: J 37088-A tool set, fuel line quick-connect fittings.