Fuel Tank: Service and Repair

Removal
1. Position vehicle on hoist.
2. Perform fuel pressure on fuel injected vehicles.
Fuel Pressure Release
3. Disconnect negative battery cable.
4. Remove fuel filler cap.

Fuel Tank Assembly L/M, Z:

Fuel Tank Assembly H, K, E, G:

5. Remove screws that secure fuel filler tube to quarter panel.

Siphon Hose Connection Location L/M, Z Except Fuel Injected Vehicles:

Siphon Hose Connection Location K,E,G Except Fuel Injected Vehicles:

6. On vehicles without fuel injection, disconnect fuel supply hose and connect either a portable holding tank or a siphon hose to the metal fuel supply tube at the right front shock tower. Drain fuel tank dry into holding tank or a properly identified "gasoline" safety container.
7. Raise vehicle and remove right rear wheel (if required).
8. On fuel injected and turbocharged models, remove draft tube rubber cap from tank sending unit and connect either a portable holding tank or a siphon hose to draft tube. Drain fuel tank dry into holding tank or properly identified "gasoline" safety container. Remove fuel supply hose from Shelby turbocharged models and drain fuel from fuel supply tube on sending unit.
9. Disconnect wiring and lines from tank.

Caution: Place shop towel over lines during removal to catch any gasoline spillage.

10. Loosen strap nut assembly and lower tank slightly, then carefully work filter tube from tank.
11. Remove strap nut assembly completely and remove tank.


INSTALLATION

1. Position fuel tank on transmission jack. Connect vapor separator/rollover valve hose and position insulator pad on fuel tank. Check that vapor vent hose is routed so that it is not pinched between tank and floor pan during installation.
2. Raise tank into position and carefully work filler tube into tank. Transmission fluid may be used as an aid to assembly.
3. Tighten strap nuts to 23 Nm (250 inch pounds). Remove transmission jack. Check that straps are not twisted or bent before or after tightening strap nuts.
4. Connect lines, draft tube cap and wiring ( fuel injected vehicles, use new hose clamps aND tighten to 1 Nm (10 inch-pounds).
5. Lower vehicle and install filler tube mounting screws.
6. Fill fuel tank, install filler cap, connect battery cable, and operate vehicle.
7. Check for leaks at hose connections.