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 the tank. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe.
Vehicles with fuel injected engines have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. This situation can be overcome with a few repeated attempts using different hose orientations.
2. Remove the exhaust pipe and exhaust shield.
3. Disconnect fuel hoses and tubes. Disconnect one end of the vapor crossover hose at the rear over the driveshaft.

NOTE: The plastic fuel tube connections are on top of the fuel tank and are inaccessible. The fuel lines must be disconnected with the tank partially removed from the vehicle.

4. Place a safety support under the tank. Remove the bolts from the fuel tank straps. Do not deform the fuel tank, fuel tank support or straps to avoid affecting fuel tank capacity and fuel pick-up.
5. Partially remove the fuel tank and disconnect the fuel lines and electrical connector from the fuel gauge sender.
6. Remove tank from the vehicle.

INSTALLATION

Fuel Tank And Lines - Exploded View:

1. Leak check the sender unit.
2. Ensure fuel vapor separator valve is installed completely on the tank top.
3. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the tank is installed.
4. Replace or install all body mounted fuel tank shields.
5. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel filler pipe hose with water base tire mounting lubricant. Install the tank onto the filler pipe hose then bring the tank into final position.
6. Bring fuel tank straps around the tank and start the attaching nut or bolt. Align tank with the straps and driveshaft.
7. Check the hoses and wiring mounted on the tank top to ensure they are correctly routed and will not be pinched between the tank and body or driveshaft.
8. Tighten the fuel tank strap attaching nuts or bolts.
9. Reconnect the fuel hoses and lines.
10. Install exhaust pipe shield and exhaust pipe.

CAUTION: Ensure that fuel tank shields are installed and are positioned correctly on the tank.

11. Replace the fuel drained from the tank.
12. Check all connections for leaks.

FUEL TANK STRAPS

Straps may be removed without removing the tank, if each strap is removed and installed one at a time and a support is provided under the tank, or by following the procedure for fuel tank removal.

CAUTION: Ensure that fuel tank shields are installed and are positioned correctly on the tank.