Fuel Tank Assembly

Fuel Tank Mounting:

Fuel Feed And Return Lines:

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Drain the fuel tank, refer to MAINTENANCE PROCEDURES/FUEL TANK DRAINING.

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.

4. Raise the vehicle on a hoist.

CAUTION:
- If nylon fuel feed or return lines become kinked, and cannot be straightened, they must be replaced.
- DO NOT attempt to repair sections of nylon fuel lines. If damaged, replace.

5. Disconnect the quick-connect fittings at the fuel level meter fuel feed and return lines:
a. Grasp both ends of one fuel line connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connection fitting. Repeat for the other fitting.

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

b. Using compressed air, blow out the dirt from the quick-connect fittings.
c. Insert the tool into the female connector, then push inward to release the male connector.
d. Repeat for the other fitting.
6. Wipe the vapor hose connection, release and move the vapor hose clamp, then disconnect.
7. Disconnect the fuel level meter electrical connection.

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

8. With the aid of an assistant, support the fuel tank and remove the front fuel tank retaining strap attaching bolts, rear fuel tank strap attaching nuts and bolts, both fuel tank retaining straps and fuel tank.
- Place the fuel tank in a suitable work place.

Fuel Pump/Sending Unit Installation:

FUEL LEVEL METER ASSEMBLY

9. Using tool J 24187 or equivalent, remove the fuel level meter assembly retaining cam, fuel level meter assembly and O-ring from the fuel tank. Discard the O-ring.
10. Inspect and clean:
- Using a clean shop towel, wipe off the male tube ends.
- Inspect all connectors for dirt and damage. Clean or replace components/assemblies as required.
- All O-ring surfaces.

INSTALLATION:

CAUTION: Care should be taken not to fold over or twist the fuel pump filter when installing the fuel level meter assembly as this will restrict fuel flow. Also, assure that the fuel pump filter does not block full travel of the float arm. Position the filter as shown in the illustration.

1. Position a new O-ring on the fuel tank.
2. Install the fuel level meter assembly and fuel level meter assembly retainer cam using tool J 24187 or equivalent.

NOTE: Assure proper location of the fuel meter tubes and rubber line insulator.

3. With the aid of an assistant, position and support the fuel tank. Install the fuel retaining straps, front attaching bolts and rear attaching bolts and nuts.
4. Tighten the front fuel tank retaining strap bolts to 34 Nm (26 lb.ft), and the rear retaining strap nuts to 34 Nm (26 lb.ft).
5. Install the vapor hose clamp.
6. Connect the fuel level meter electrical connector.

WARNING: To reduce the risk of fire and personal injury:
- Before connecting fuel line fittings, always apply a few drops of clean engine oil to the male tube ends. This will ensure 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).

7. Connect the fuel feed and return line quick-connect fittings.
a. Apply a few drops of clean engine oil to the male connector tube ends.
b. Push the connectors together to cause the retaining tabs/fingers to snap into place.
c. Once installed, pull on both ends of each connection to make sure connection is secure.
8. Lower the car.
9. Add fuel and install the fuel filler cap.
10. Connect the negative battery cable.
11. Turn the ignition ON for two seconds, then turn it OFF for five seconds. Again turn the ignition ON and check for fuel leaks.