Fuel Tank: Service and Repair

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL

Fuel Tank:

1. Drain fuel from the fuel tank prior to fuel tank removal.
2. Raise vehicle on hoist.
3. Remove the exhaust system as required.

NOTE: The nylon fuel tube connections are on top of the fuel tank and are inaccessible. They must be disconnected with the fuel tank partially removed from the vehicle.

4. Disconnect fuel tank to filler pipe hose and vent hoses connecting the fuel tank filler pipe to fuel tank. Disconnect one end of the vapor crossover hose at the rear over the driveshaft.
5. Place a safety support under the fuel tank. Remove the bolts from the fuel tank support straps. To avoid affecting fuel capacity and/or fuel pickup take precautions not to deform the fuel tank or fuel tank support straps.
6. Partially remove the fuel tank and disconnect the rear fuel supply return and vapor tubes and electrical connector from the fuel gauge sender, if required.
7. Remove fuel tank from the vehicle.

INSTALLATION

1. Before proceeding, check the following items:
a. Leak check the fuel tank sending unit. If necessary, tighten with Fuel Tank Sender Wrench D84P-9275-A or equivalent.
b. Ensure fuel vapor valve is properly installed on the fuel tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the fuel tank is installed.
d. Replace or install all body-mounted fuel tank shields.
2. Check the hoses and wiring mounted on the fuel tank top to ensure they are correctly routed and will not be pinched between the fuel tank and body or driveshaft.
3. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel tank to filler pipe hose with water-base tire mounting lubricant. Install the fuel tank onto the fuel tank to filler pipe hose, then bring the fuel tank into final position.
4. Bring fuel tank support straps around the fuel tank and start the retaning bolts. Align fuel tank with the fuel tank support straps and driveshaft.

CAUTION: Make sure the fuel vent hose is positioned above the vent retainer and not contacting the driveshaft.

5. Tighten the fuel tank support straps retaining bolts to 29-41 Nm (22-30 lb ft).
6. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel return (if present) and vapor vent connections are made correctly. Trace the various lines to the engine and ensure the proper lines are connected.

CAUTION: Ensure that fuel tank shield is installed.

7. Install exhaust system.
8. Lower vehicle.
9. Install fuel filler neck to body bolt. Tighten to 2.7-3.7 N.m (24-32 lbs-in).
10. Replace fuel.
11. Check all connections for leaks.