Fuel Tank: Service and Repair

Fuel Tank:

FUEL TANK

Precautions
a. Before starting the job, be sure to carry out the following.
- Place "No Fire" signs near the working area.
b. Be careful not to spill fuel on the floor.

Removal
1. Fold down rear seat back and turn up carpet.
2. Remove access hole covers.
3. Disconnect fuel pump and gauge sending unit electrical connectors.
4. Start engine.
5. Crank engine an additional 5 seconds after it stalls.
6. Turn ignition OFF. Disconnect ground cable from battery.
7. Drain fuel from tank into a suitable container.
8. Remove muffler, rear suspension crossmember and rear differential assembly. (4WD model only).

Fill Pipe Removal:

9. Remove clamp and disconnect fuel filler hose from fuel filler pipe.

Vent Hose Removal:

10. Remove clamp and disconnect air vent hose from fuel filler pipe.

Breather Hose Removal:

11. Loosen clips and disconnect air vent hoses from fuel filler pipe.

Fuel Line Attachment:

12. Loosen clamps and disconnect air breather hoses and evaporation hose from pipes. (4WD model).

Tank Removal:

13. While holding fuel tank, remove band retaining bolts and remove tank.
Caution: Two men required to perform step 12 above.
13. Disconnect harness connector from fuel pump assembly. On 4 WD models, also disconnect harness connector from fuel meter unit. Have helper support fuel tank when disconnecting harness.

Installation
1. Reverse procedure to install. Observe the following:
2. When installing fuel tank, have a helper hold tank while connecting hoses and harness connector.
3. Before tightening band mounting bolts, make sure hoses, harnesses, etc. are not caught between fuel tank and car body.











4. Install hose and tube holddown clips at positions indicated in the figure.