Fuel Tank: Service and Repair

Fuel Tank And Components:

REMOVAL

Fuel Pump Access Cover:

1. Remove the fuel pump access cover.

Fuel Pump Harness Connector Location:

2. Disconnect the fuel pump and fuel gauge connectors.
3. Start and run the engine until it stalls, then turn the ignition switch to OFF.
4. Disconnect the battery negative terminal.
5. Remove the fuel tank cap.
6. Drain the fuel.

High Pressure Fuel Hose Connector Location:

7. Disconnect the fuel high pressure line.

CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the line.

8. Disconnect the return line and vapor hose.
9. Detach the fuel filler hose and leveling hose.
10 Remove the fuel tank mounting nuts.

CAUTION: Insure that there is something in position to restrain the tank from falling prior to removing the tank mounting nuts.

11. Remove the fuel tank.

INSTALLATION

1. Install the fuel tank and secure with the mounting nuts.
2. Connect the leveling hose, from the tank, approximately 1.6 in. (40mm) onto the filler neck.
3. Connect the vapor hose and return line.

High Pressure Hose Connection:

4. Connect the high pressure hose.

CAUTION: When tightening the flare nut, be careful not to bend or twist the line.

Torque value: 25 ft.lbs. (35 Nm)

5. Connect the electrical fuel pump and fuel gauge unit connector.
6. Tighten the drain plug.

Torque value: 10 - 15 ft.lbs. (13 - 20 Nm)

Note: On vehicles manufactured after march 25, 91 washer material was changed to aluminum. This requires the use of a stronger drain plug (identified by a "7" stamped on the head) and a higher torque value.

Higher torque value: 12 - 19 ft.lbs. (17 - 26 Nm)

7. Connect the negative battery terminal.