Fuel Tank: Service and Repair

REMOVAL

WARNING: Explosion and fire hazard. Observe the following precautions when working on the fuel tank.

^ Be sure area is well ventilated.
^ Always relieve fuel system pressure before disconnecting fuel lines.
^ Do not smoke or light any cigarettes where odor of fuel vapor is present.
^ Disconnect battery and do not create any sparks or flames where odor of fuel vapor is present.
^ An empty fuel tank contains an explosive mix of fuel vapors and air. If tank repair is necessary that involves any welding or soldering, clean inside of tank with solution of detergent and water and then use steam to displace any residual vapors that may remain.

Fuel Tank Assembly:

1. Relieve fuel system pressure by starting engine with fuel pump relay (circuit open relay) disconnected and let run until engine dies. Then slowly and carefully remove hose on outlet side of fuel filter. Cover with a clean rag while removing hose, to avoid spraying fuel in your face.

2. Lift rear of vehicle and support on jackstands.

3. Drain the fuel from the tank into a suitable container.

4. Lift up rear mat, and remove fuel pump access cover.

5. Disconnect fuel pump electrical connector.

6. Remove the fuel hoses. Be carefull when removing, some residual pressure may be present, expecially if there is some restriction in the fuel filter.

7. Remove fuel pump from tank.

8. Disconnect fuel filler tube and filler vent hose from tank.

9. Disconnect evaporative hoses.

10. Support tank and remove retaining straps.

11. Lower tank out of vehicle.

Install in reverse order.