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. Depressurize fuel system.
2. Fuel should be drained from fuel tank as completely as possible prior to fuel tank removal. On unleaded gasoline vehicles, this is accomplished by siphoning or pumping fuel out the fuel tank filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00012 or equivalent. Vehicles 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.
3. Loosen fuel tank filler pipe and vent hose clamps at fuel tank and remove hoses from fuel tank.
4. Place a safety support under fuel tank and remove bolts from rear of fuel tank support straps (9092). The fuel tank support straps are hinged at the front and will swing 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. Refer to Push Connect Fitting Removal.
6. Remove fuel tank from vehicle.

Installation






NOTE: If fuel tank sending unit and pump has been removed, the 0-ring seal on unleaded gasoline vehicles or gasket on Flexible Fuel vehicles must be replaced.

1. Before proceeding, check following items:
a. Leak check sender unit. If necessary, use Fuel Tank Sender Wrench T74P-92 75-A or equivalent.
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. Route lines through clip on fuel tank.
2. Place fuel tank in its proper position in vehicle.
3. Bring fuel tank support straps around fuel tank and start retaining bolt. Align fuel tank as far forward in vehicle as possible while securing retaining bolts.

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

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 29-41 N.m (22-30 lb-ft).
6. Install fuel filler hoses which connect fuel tank to fuel tank filler pipe Install hose clamps and tighten to 2.7-3.7 N.m (24-32 lb-in).
7. Replace fuel drained from fuel tank.
8. Start engine and check all connections for leaks.