Fuel Tank Assembly
Fuel Fillpipe Replacement.:
Fuel Tank Replacement.:
Removal Of Fuel Pump/sender Module.:
Check Ball Location And Replacement View.:
Fuel Hoses, Lines And Fuel Tank Exploded View.:
DRAINING FUEL TANK
Draining fuel tank requires removal of the filler neck checkball to allow siphoning. REMOVAL OF THE FUEL TANK is necessary to replace the fuel tank checkball. Prior to tank installation, insert the checkball back into the filler neck.
WARNING: Whenever the fuel tank requires removal, the fuel level should not be more then 3/4 full. If the fuel tank is more than 3/4 full, use extreme care when removing hoses.
PRECAUTIONS
WARNING
Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.
Anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
Whenever fuel line fittings are loosened or disconnected, wrap a shop towel cloth around fuel lines to collect fuel, then relieving fuel place cloth in an approved container.
Make sure the vehicle is properly supported and squarely positioned on hoist. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.
REMOVAL
1. Remove fuel fill cap and position vehicle on a hoist and block wheels.
2. Disconnect negative battery cable at battery.
3. Release fuel pressure at valve using gage bar kit SA9127E (or equivalent) located on fuel delivery line to engine and install cap.
4. Raise rear of vehicle approximately 28 inches to a comfortable working position. This allows the fuel to flow forward in the tank away from the fill hose opening.
WARNING: Whenever fuel tank fill neck hose is removed, catch fuel in an approved container. The container opening must be a minimum of 300 mm (12 in.) diameter to adequately catch the fluid.
5. Position an approved drain container with enough capacity to hold the fuel under the fill neck. Loosen the fuel filler neck connecting tube clamp at rear of tank. Wrap a shop towel around fuel filler neck connecting tube and slowly remove fuel filler neck connecting tube from fuel tank.
NOTE: Draining fuel tank requires removal of the filler neck checkball to allow siphoning. Prior to tank installation, insert the checkball back into the filler neck.
6. Using the large round end of a 1/2 in. socket extension (approximately 18 in.) long, push the filler neck check ball into tank.
NOTE: Clean fuel filler neck at tank and surrounding area before disconnecting filler neck tube to avoid possible contamination of the fuel system.
7. Position a siphon hose into the fuel tank through the fuel filler opening. Place other end into an approved container with enough capacity to hold fuel in tank. Siphon fuel from tank.
8. Remove fill neck bracket fastener at left hand side rear fame rail. Loosen fuel vent hose clamp at tank.
NOTE: It easier to remove the hoses off the tank than to pull them off the steel vent and fill tubes.
NOTE: Do not attempt to repair sections of nylon fuel line. If damaged, replace.
9. Disengage the fuel supply and return line quick connects by pinching the two plastic tangs together. Grasp both ends of one fuel line connection and twist 1/4 turn in each while pulling them apart. Separate the rubber vent line connection by grasping tank assembly line and pushing away rubber connector using a small open end wrench.
WARNING: Use extreme care when removing the fuel tank because it retains approximately four liters (one gallon) of fuel when completely drained.
CAUTION: Do not bend fuel tank retaining straps during tank removal because this may damage them.
10. With the aid of an assistant, remove the two support strap fasteners at rear of tank and lower fuel tank with support panel approximately eight inches to disconnect the electrical connection at top of tank.
11. Remove the fuel tank from vehicle.
INSTALLATION
1. Remove the filler neck checkball from inside the fuel tank and inspect it for cracks and holes. If damaged, replace the filler neck checkball.
2. Insert the filler neck checkball back into the tank's filler neck cavity. The ball must be installed from the inside by reaching through the tank's fuel pump module opening.
NOTE: The plastic ball supports can be carefully separated to allow for checkball installation.
3. With the aid of an assistant, position the fuel tank under vehicle. Attach the electrical connector.
4. Install the two fuel tank retaining straps and support panel. Install the two rear attaching bolts.
- Torque: 47 Nm (35 ft lbs)
CAUTION: To prevent driver's side quarter panel deflection, the fill neck and fuel tank must be properly aligned during installation.
CAUTION: The steel band clamps used on fuel lines are designed to prevent hose damage and must be replaced only with an original equipment (O.E.) parts.
WARNING: Whenever fuel lines are disconnected at connectors, lubricate the male line ends with clean engine oil. Holding male end of the line, firmly press on female coupler until a click is heard, then pull back to confirm engagement. Pinched, kinked or damaged fuel lines must be replaced.
5. Attach the fuel fill and vent lines and install clamps. Align fill neck and tank. Install fill neck tube and bracket fastener. Insert vent lines into rubber boot until white marks on tube align with side of boot.
- Clamps Torque: 2 Nm (18 in lbs)
- Fill Neck Bracket Torque: 6 Nm (53 in lbs)
6. Apply a few drops of clean engine oil to the male connector tube ends. Push connectors together to cause the retaining tabs to lock in place. Once installed, pull on both ends of each connection to make sure it is secure.
7. Lower vehicle on hoist. Add fuel, install filler cap and connect battery negative terminal.
8. Prime fuel system.
a. Cycle ignition "ON" for 5 seconds and then "OFF" for 10 seconds.
b. Repeat step 8a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 8a - 8c.
9. Run engine and check fuel system for leaks.
NOTE: It may be necessary to turn the ignition switch "ON" and "OFF" several times to prime the fuel system.