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. Fuel should be drained from tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping fuel out through one of the fuel filler hoses.
2. Disconnect fuel hoses and tubes. On vehicles equipped with fuel injection, refer to the push connect fitting procedure. On EFI equipped vehicles, the electric fuel pump must be removed prior to fuel tank strap removal.
3. Disconnect electrical hookup to fuel tank sender unit. On some vehicles, electrical connection is inaccessible on top of tank and no intermediate connection point is provided. In these cases, electrical connector must be disconnected from fuel sender with tank partially removed from vehicle.
4. Place a safety support under tank and remove bolts or nuts from one end of fuel tank straps. The straps are hinged at one end. Remove bolts from unhinged end and swing straps out of the way.
5. Partially remove tank and disconnect fuel lines and electrical connector from fuel gauge sender, if required.
6. Remove tank from vehicle.

Installation

1. Before proceeding, check following items:
a. Leak check sender unit.
b. Ensure fuel vapor separator valve is installed completely on tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after tank is installed.
2. Place fuel tank in its proper position in vehicle.
3. Bring fuel tank straps around tank and start attaching nut or bolt. Align tank with straps.
4. Check hoses and wiring mounted on tank top, to be sure they are correctly routed and will not be pinched between tank and body.
5. Tighten fuel tank strap attaching bolts to specification.
6. Reconnect fuel tank hoses and lines. Be certain that fuel supply, fuel return and vapor vent connections are made correctly. Trace various lines to the engine.
7. Reconnect electric connections.
8. Install fuel filler hoses which connect fuel tank to fuel filler pipe. Install new hose clamps and tighten to specification.
9. Replace fuel drained from tank.
10. Check all connections for leaks.