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

1. Depressurize the fuel system.
2. Drain fuel from the fuel tank prior to fuel tank removal.
3. Disconnect battery ground cable.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy.

4. Raise vehicle on hoist.
5. Disconnect fuel hoses and tubes.
6. On vehicles equipped with a fuel tank filler pipe retainer which fastens the fuel tank filler pipe to the fuel tank, remove the screw retaining the fuel tank filler pipe retainer to the fuel tank flange.
7. Disconnect electrical hookup to the fuel tank sender unit.
8. Place a safety support under the fuel tank. Remove the nuts from one end of the fuel tank support straps. The fuel tank support straps are hinged at the other end out of the way.
9. Remove fuel tank from the vehicle.

INSTALLATION

Fuel Tank:

1. Before proceeding. check the following:
a. Leak check the sender unit. If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A.
b. Ensure fuel vapor valve is properly installed on the fuel tank top.
c. Make all required connections which will be inaccessible after the fuel tank is installed.
2. Place the fuel tank in its proper position in the vehicle. For most models, lubricate the fuel tank filler pipe with water base tire mounting lubricant. Install the fuel tank onto the fuel tank filler pipe then bring the fuel tank into final position.

CAUTION: If equipped with heat shield, make sure it is installed with straps and properly positioned on the tank.

3. Bring fuel tank support straps around the fuel tank and start the retaining nut or bolt. Align fuel tank with the fuel tank support straps and check clearance to frame and underbody.
4. 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.
5. Tighten the fuel tank support strap retaining nuts to 29-41 Nm (22-30 lb ft).
6. Fasten fill pipe retainer, if removed.
7. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel return, and vapor vent connections are made correctly. Trace the various lines to the engine and refer to the applicable system illustrations to ensure the proper lines are connected.
8. Connect electrical connections.
9. Lower vehicle.
10. Replace fuel drained from the fuel tank.
11. Connect battery ground cable.
12. Check all connections for leaks.