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 completely drained from fuel tank prior to removal. Siphon or pump fuel out through the fuel tank filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00012 or equivalent.
2. Disconnect fuel hoses and tubes.
3. Disconnect electrical hookup to fuel tank sending unit and pump.
4. Place a safety support under fuel tank and remove bolts or nuts from one end of fuel tank support straps. The fuel tank support straps are hinged at one end. Remove bolts from unhinged end and swing straps out of the way.
5. Partially remove fuel tank and disconnect fuel lines and electrical connector from fuel tank sending unit and pump, if required.
6. Remove fuel tank from vehicle.

Fuel Tank Assembly:

INSTALLATION

1. Before proceeding, check following items:
a. Leak check sender unit. If necessary, use Fuel Tank Sender Wrench T74P-9275-A.
b. Ensure fuel vapor valve is installed completely on fuel tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after fuel tank is installed.
2. Place fuel tank in its proper position below vehicle.

CAUTION: If equipped with heat shield make sure it is installed with fuel tank support straps and positioned correctly on the fuel tank.

3. Bring fuel tank support straps around tank and start retaining nut or bolt. Align fuel tank with fuel tank support straps.
4. Check hoses and wiring mounted on fuel tank top, to ensure they are correctly routed and will not be pinched between fuel tank and body.
5. Tighten fuel tank support strap retaining bolts to 34-55 Nm (26-40 lb ft).
6. Connect fuel tank hoses and lines. Verify that fuel supply, fuel return and vapor vent connections are made correctly. Trace various lines to the engine. Refer to applicable system illustrations to ensure proper lines are connected.
7. Connect electrical connections.
8. Install fuel tank to filler pipe hoses which connect fuel tank to fuel tank filler pipe. Install new hose clamps and tighten to 3.4-4.5 Nm (31-39 lb in).
9. Replace fuel drained from fuel tank.
10. Check all connections for leaks.