Fuel Tank: Service and Repair

WARNING: Before attempting to remove the fuel tank, observe the following precautions:
- Be sure to have a Class B, dry chemical fire extinguisher close to the work area.
- Wear safety glasses.
- Siphon or pump fuel into an explosion-proof container to prevent the possibility of explosion or fire.

REMOVAL:

1. Raise vehicle to gain access to the fuel tank.
2. Drain fuel from tank into a suitable container utilizing either the fuel pump to pump the fuel or a siphon hose.

Fuel Tank - Exploded View:

3. Remove fuel inlet pipe protector shields.
4. Remove filler cap.
5. Disconnect fuel pump and gauge sending unit wiring harnesses.
6. Disconnect filler neck/overflow pipe from tank.
7. Disconnect fuel supply and return hoses from tank pipes.
8. Disconnect breather hose from tank pipe.
9. Cover openings in tank to prevent dirt from entering the tank.
10. Support the fuel tank with a transmission jack. DO NOT dent the bottom of the tank.
11. Remove the fuel tank mount bolts. The fuel tank protector and the Fuel Tank will come off as one unit.
12. Lower jack and tank from underside of vehicle.

INSTALLATION:

1. Ensure that tank cushions (pads) are correctly positioned on tank topside. Use adhesive to hold them in place, if necessary.
2. Position the Fuel Tank and the fuel tank protector on transmission jack and align tank under rear of vehicle.
3. Jack tank into place. DO NOT dent fuel tank.
4. Install the Fuel Tank mount bolts. Torque bolts to 19 ft.lbs. (25 N-m).
5. Connect breather hose.
6. Connect fuel supply/return hoses to tank pipes.

Installing Fuel Hoses:

7. Torque fuel supply hose fitting to 22 ft.lbs. (30 N-m).
8. Install new gasket and connect filler neck/overflow pipe to tank. Torque screws to 26 in.lbs. (2.9 N-m).
9. Connect fuel pump and gauge sending unit wiring harnesses.
10. Install filler cap and fuel inlet pipe protective shields.
11. Lower vehicle and fill tank with gasoline.
12. Start engine and check for fuel leaks.