Service Procedure

FIGURE 1:

Refer to Figure 1 for visual aid during this procedure.

1. Disconnect the negative battery cable.

2. Remove the fuel filler cap.

3. Drain the fuel tank and store fuel for reuse.

4. Remove hose clamp and hose from return pipe.

5. Remove hose clamp and fuel filter pipe hose.

NOTE Remove clamp and hose only at pipe connection to vehicle body. Leave hose attached to fuel tank at this time.
6. Remove fuel filler hose clamps and hose.

7. Remove hose clamp and breather hose.

8. Remove hose clamps and fuel tankto-evaporator pipe hose.

9. Disconnect the sending unit wire from the fuel tank terminal.

10. Disconnect the fuel pump wire from the fuel pump terminal.

11. Remove four 8 mm fuel tank mounting bolts.

12. Remove the fuel tank assembly from the vehicle.

13. Remove the fuel pump as follows:

a. Disconnect the fuel pump hose from the fuel feed pipe, leaving the hose connected to the fuel pump outlet pipe. Keep the clip for reuse.

b. Remove eight retaining screws.
c. Remove the fuel pump from the fuel tank.

14. Remove five retaining screws and remove the fuel tank sending unit.

15. Install the fuel tank sending unit into the new fuel tank assembly, using the new gasket and five screws provided in the kit.

16. Install the fuel pump into the new fuel tank assembly, using the new gasket and eight screws provided in the kit.

17. Using existing clamps, install the following hoses:

a. Connect the fuel pump hose to the fuel feed pipe.

b. Remove the fuel filter pipe hose from the old fuel tank, and install it to the new fuel tank.

c. Install the new fuel tank to the vehicle. Reconnect the sending unit wire to the fuel tank terminal. Reconnect the fuel pump wire to the pump terminal.
d. Connect the fuel feed hose to the fuel filter pipe on the vehicle body.

e. Install the fuel filler hose and breather hose.

f. Install the fuel tank-toevaporator pipe hose.

18. Reconnect the negative battery cable.
19. Fill new fuel tank with fuel drained previously. Install fuel filler cap.

FIGURE 2:

20. Affix campaign identification label to inside of driver's door (Figure 2). Using a ball-point pen, fill in label with campaign number and dealer code.