Fuel Tank Removal and Installation

To replace the Fuel Tank:

WARNING: Fuel may be expelled during this procedure. Use a clean rag to soak up any spilled fuel. Do not disconnect any wires that could cause electrical sparks. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.

Fuel Tank:

1. Disconnect battery ground strap.
2. Remove luggage compartment cover.
3. Remove access cover to fuel gauge sending unit.

Tank Sending Unit Connections:

4. Disconnect from fuel gauge sending unit (see image):
#1 fuel supply line to main fuel pump
#2 fuel return line to fuel tank
#3 fuel gauge and fuel transfer pump electrical connector

Fuel Gauge/Transfer Pump Tool:

5. Remove fuel gauge sending unit with special tool US 2012A, or equivalent.
6. Drain tank through fuel gauge sending unit opening, drain fuel into a clean fuel-safe container.
7. Raise vehicle on a hoist.
8. Place a suitable support stand under fuel tank.

Fuel Tank And Filler Pipe Hose:

9. Loosen lower clamp of connecting hose between fuel tank and filler pipe.

Fuel Tank Retaining Straps:

10. Remove nuts securing fuel tank retaining straps.
11. Disconnect connecting hose between fuel tank and filler pipe, support tank with stand.
12. Loosen breather hose clamps.
13. Disconnect the breather hoses from tank.
14. Installation is the reverse of removal.
15. When installing fuel tank, torque retaining strap nuts to:

17 ft.lbs. (23 Nm)

16. Fill fuel tank and check for leaks, repair any leaks immediately.