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
Fuel Tank And Lines - Exploded View:
1. Siphon or pump fuel out through one of the fuel filler hoses.
2. Disconnect fuel hoses and tubes.
3. Disconnect electrical hookup to fuel tank sender unit.
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 the following items:
a. Leak check sender unit.
b. Ensure fuel vapor separator valve is installed completely on tank top.
c. Make all the 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.
3. Bring fuel tank straps around tank and start attaching nut or bolt. Align tank with straps.
CAUTION: If equipped with heat shield make sure it is installed with straps and positioned correctly on the tank.
4. Check hoses and wiring mounted on tank top, ensure they are correctly routed and will not be pinched between tank and body.
5. Tighten fuel tank strap attaching bolts to 25-39 lb. ft. (34-54 N-m).
6. Connect fuel tank hoses and lines. Verify that fuel supply, fuel return and vapor vent connections are made correctly.
7. Connect electrical connections.
8. Install fuel filler hoses which connect fuel tank to fuel filler pipe. Install new hose clamps and tighten to 25-33 lb. ft. (34-45 N-m).
9. Replace fuel drained from tank.
10. Check all connections for leaks.
FUEL TANK STRAPS
REMOVAL
NOTE: Straps may be removed, and/or replaced 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. 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.
1. To remove strap, 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 the bottom of bracket. If it does not, the 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.