Fuel Tank Assembly

Fuel Tank:

Filler Pipe:

REMOVE OR DISCONNECT

1. Relieve fuel system pressure. Refer to Fuel System Pressure Relief.
2. Raise vehicle and suitably support.

CAUTION: 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

3. Drain fuel tank (refer to Fuel Tank Draining).

NOTE: If nylon fuel feed or return pipes become kinked and cannot be straightened, they must be replaced. Do not attempt to repair sections of nylon fuel pipes. If damaged, replace.

4. Fuel feed pipe at fuel filter and return pipe near fuel filter.

a. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick-connect fitting. Repeat for other fitting.

CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.

b. Squeeze plastic tabs of male end connector of fuel filter, then pull connection apart.
c. Repeat for fuel return pipe fitting.

5. Fuel fill hose and vent hose at fuel tank.
6. Fuel sender electrical connector.
7. Exhaust heat shield screws and reposition shield.

NOTE: Do not bend fuel tank retaining straps, as this may damage straps.

8. With the aid of an assistant, support fuel tank and remove front fuel tank retaining strap attaching bolts (2), rear fuel tank strap attaching bolts (2) both fuel tank retaining straps.
9. Lower tank and disconnect EVAP pipe.

- Place fuel tank in a suitable work area.
- Using a clean shop towel, wipe off male pipe end.
- Inspect all connectors for dirt and darnage. Clean or replace components/assemblies as required.

10. Fuel sender assembly (refer to Modular Fuel Sender Assembly/Service and Repair).

INSTALL OR CONNECT

1. Fuel sender assembly. Refer to Modular Fuel Sender Assembly/Service and Repair.

NOTE: Assure proper location of fuel sender pipes.

2. With the aid of an assistant, raise fuel tank and connect EVAP pipe. Install fuel tank retaining straps (2), front attaching bolts (2) and rear attaching bolts (2).

Tighten:

- Front fuel tank retaining strap bolts (2) to 34 Nm (25 lb. ft.).
- Rear fuel tank retaining strap bolts (2) to 34 Nm (25 lb. ft.).

3. Exhaust heat shield and attaching screws.
4. Fuel sender electrical connector.
5. Fuel fill hose and vent hose to fuel tank.

CAUTION: To reduce the risk of fire and personal injury: Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe 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).

6. Fuel feed and return pipe quick-connect fittings.

a. Apply a few drops of clean engine oil to the male connector pipe ends.
b. Push 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.

7. Lower car.
8. Add fuel and install fuel filler cap.

- Turn ignition switch to "ON" position for two seconds, then turn to "OFF" for five seconds. Again, turn to "ON" position and check for fuel leaks.