Fuel Tank: Service and Repair

Fuel Tank Shield:

Fuel Tank:

WARNING: Gasoline mixed with water and water mixed with emulsifying agent needs to be treated as a hazardous material. The material needs to be handled in accordance with all applicable local, state, and federal laws and regulations.

NOTE: The fuel tank should be purged before being repaired.

REMOVAL PROCEDURE
1. Remove the fuel tank from the vehicle.
2. Remove the fuel gage sending and pump unit.
3. Remove all the remaining fuel from the tank.

INSTALLATION PROCEDURE
1. Inspect the tank for any remaining fuel.
2. Pour tap water into the tank.

- Move the tank to the flushing area (wash rack).
- Agitate the water vigorously.
- Then drain the tank.

3. Pour the gasoline emulsifying agent into the tank. Use an available emulsifying agent.
4. Add water to the fuel tank.

- Refer to the emulsifying agent specifications for the mixture ratio.
- Agitate the mixture for ten minutes.
- Drain the tank completely.
- Fill the tank with water until it overflows.
- Completely flush out any remaining mixture.
- Drain the fuel tank.
- Use an explosion meter (if available) in order to check for a negative reading.
- Perform the required service work.

5. Repair fuel tank.
6. Install the fuel gage sending and pump unit.
7. Install the fuel tank onto vehicle.
8. Check for leaks.

INSTALLATION PROCEDURE
1. Install a new seal ring.

NOTE: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

2. Reinstall sender using tool J366O8
3. Raise tank slightly.
4. Reconnect the fuel and vapor hoses and the electrical connections at the sender. Ensure the ground strap is also reinstalled to the body.
5. Raise the tank fully.
6. Reinstall the fuel tank filler neck to the tank.
7. Tighten the clamp.

NOTE: The strap nuts must be tightened by steps, alternating between the four nuts until the specified torque is reached. Otherwise, the bottom of the tank will flex upward and the fuel gage will indicate fuel remaining in the tank when the tank runs dry.

8. Install the fuel tank brackets with insulator strips in place.

Tighten
Tighten the strap nuts to 45 Nm (33 lb. ft.).

9. Install the fuel tank shield
10. Lower the vehicle.
11. Replenish fuel.
12. Reinstall fuel tank filler cap.
13. Reconnect the negative battery cable. If a memory retention device was not used please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
14. Check for leaks.