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 as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 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 fill and vent hoses connecting the filler pipe to tank. 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. In these cases, 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. Take care not to deform the fuel tank, fuel tank support or straps to avoid affecting fuel tank capacity and or fuel pick-up.
5. Partially remove the tank and disconnect the fuel lines and electrical connector from the fuel gauge sender, if required.
6. Remove tank from the vehicle.
Installation
1. Before proceeding, check the following items:
a. Leak check the sender unit. If necessary, tighten with Fuel Tank Sender Wrench D84P-9275-A or equivalent.
b. Ensure fuel vapor separator valve is installed completely on the tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the tank is installed.
d. Replace or install all body mounted fuel tank shields.
2. 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.
3. Bring fuel tank straps around the tank and start the retaining nut or bolt. Align tank with the straps and driveshaft.
4. 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.
CAUTION: Make sure the fuel vent hose is positioned above the vent retainer and not contacting the driveshaft.
5. Tighten the fuel tank strap retaining nuts or bolts to 28-40 Nm (20-30 lb-ft).
6. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel return, (if present) and vapor vent connections are made correctly. Trace the various lines to the engine and refer to the applicable system illustrations to ensure the proper lines are connected.
7. Install exhaust pipe shield and exhaust pipe.
CAUTION: Ensure that fuel tank shields are installed and are positioned correctly on the tank. Refer to the applicable system Illustration.
8. Replace fuel drained from the tank.
9. Check all connections for leaks.