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. Prior to fuel tank removal, fuel should be drained from tank. Disconnect the fuel filler pipe from rubber hose and siphon or pump fuel out though remaining rubber hose.
Vehicle with fuel injected engines have reservoirs inside fuel tank to maintain fuel near fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching bottom of fuel tank. This situation can be overcome with a few repeated attempts using different hose orientations.
2. Loosen filler hose pipe and vent hose clamps at tank and remove hoses from tank.
3. Place a safety support under tank and remove bolts from one end of fuel tank straps. The straps are hinged at the other end.
4. Partially remove tank and disconnect fuel lines and electrical connector from fuel gauge sender/pump assembly.
5. Remove fuel tank from vehicle.
INSTALLATION
1. Check the following:
a. Leak check on sender unit.
b. Ensure that fuel separator valve is installed completely on tank top.
c. Make all line 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 bolt. Align tank as far forward in vehicle as possible while securing attaching bolts.
4. Check hoses and wiring mounted on tank top, to ensure they are correctly routed and will not be pinched between tank and body.
5. Tighten fuel tank strap attaching bolts to 21-29 lb. ft. (28-40 N-m).
6. Install fuel filler hoses which connect fuel tank to fuel filler pipe. Install hose clamps and tighten to 25-33 lb. ft. (34-45 N-m).
7. Replace fuel drained from tank.
8. Check all connections for leaks.
FUEL TANK STRAPS
Fuel tank straps can be replaced without removing the tank, by removing one strap at a time, while providing support under fuel tank.
NOTE: Straps may be removed or installed by following procedures above, fuel tank removal and installation.
The hinged end of the strap attachment holds the strap in place after the fuel tank is removed. This hinged end uses a pin type attachment through a loop in the end of the strap.
REMOVAL
1. Push strap up into bracket until pin lines up with large hole. There is a guide and stop inside bracket to assist in aligning strap for removal and installation of pin.
2. Push pin out of large hole in side of bracket by inserting a small drift pin or punch into small hole in opposite side of bracket.
NOTE: A magnetized screwdriver is helpful to draw pin out of large opening in bracket if pin does not line up properly.
INSTALLATION
1. Push strap into bracket opening.
2. Insert pin into loop in strap.
3. Pull strap down until pin is fully seated on bottom of bracket.
CAUTION: The pin must rest flat against bottom of bracket. If it does not, fuel tank could be damaged. Do not install tank. Attempt to position pin so that it will seat properly. If unsuccessful, remove pin and strap. Check for, and remove any obstruction that may be inside bracket. Check to ensure pin is correct length.