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. Disconnect the battery negative cable.
2. Release pressure from the fuel system.
3. Remove as much fuel as possible from the tank using a safety-approved pump.

CAUTION: The fuel level in the tank must be below the level of the filler neck.






4. Remove the filler door/filler neck housing attaching screws and the filler door.






5. Remove the filler neck to housing attaching screws. Remove the filler cap and tether assembly.
6. Raise the vehicle.






7. Remove the filler neck support bracket attaching bolt.






8. Disengage the fuel supply and return lines from the routing clip located above the right halfshaft.
9. Support the fuel tank on a suitable jack. Secure the tank to the jack with safety straps.






10. Remove the fuel tank shield attaching screws and the fuel tank strap attaching bolts.
11. Lower the fuel tank slightly and disconnect the following:






Vapor line






Fuel level sending unit connector






Fuel pump wiring connector






Fuel supply line

NOTE: If necessary, refer to the hairpin clip removal procedure.







Fuel return line

NOTE: Fuel Line Remover T82L-9500-AH, or equivalent. If necessary, refer to the procedure in this section for tool usage or the alternate procedure that does not require the tool.

12. Move the fuel tank to the left to separate it from the filler neck.
13. Push the tank rearward to clear the tank shield. Lower it from the vehicle.

Installation

1. Raise the fuel tank.
2. Coat the filler neck with SAE 1OW-40 engine oil. Engine oil only must be used.
3. Guide the filler neck into the tank grommet and push the tank into position.
4. Connect the following:
Vapor return line
Fuel supply line
Fuel return line
Fuel pump wiring connector
Fuel level sending unit connector
5. Raise the tank into position. Position the tank straps and install the attaching bolts.
6. Remove the jack used to support the fuel tank.
7. Install the filler neck support bracket attaching bolt.
8. Install the fuel supply and return lines in the routing clip.
9. Lower the vehicle.
10. With the filler neck and filler cap tether in position, install the filler neck attaching screws.
11. Install the filler neck housing attaching screws.






12. Position the filler door and install the attaching screws. Before tightening the filler door attaching screws, adjust the position of the door to fit the body panel opening.
13. If fuel was removed from the tank, pump it back into the tank.
14. Connect the battery negative cable.
15. Start the engine. Check for leaks at the tank fuel lines.