Fuel Tank: Service and Repair

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL

Fuel Pump Relay:

1. Relieve the fuel line pressure.
a. Disconnect the fuel pump relay.
b. After the engine stalls, turn OFF the engine.
c. Connect the fuel pump relay.

Fuel Sending Unit Connectors:

2. Disconnect the negative battery cable.
3. Remove the rear seat cushion.
4. Disconnect the sending unit electrical connector.
5. Remove the four attaching screws and the sending unit access cover.
6. Remove clamps securing fuel supply and fuel return line hoses. Remove the hose from the sending unit.

Fuel Tank Drain Plug:

7. Raise the vehicle and support it with safety stands.
8. Remove the drain plug and drain the fuel from the fuel tank into an approved safety container.

Parking Brake Cable Retaining Brackets:

9. Remove three clamps and vapor hoses at the fuel tank filler neck assembly.
10. Remove the clamp and fuel tank filler neck hose at the filler neck assembly.
11. Remove two parking brake cable retaining brackets from the chassis to gain access to the fuel tank.

Fuel Tank Mounting Strap:

12. Remove the fuel tank mounting strap.
13. Support the fuel tank and remove the three attaching bolts and brackets.

Fuel Tank Removal/Installation:

14. Remove the fuel tank.

INSPECTION

Repair or replace the fuel tank if any cracks or corrosion is detected.

WARNING: Before repairing, clean the fuel tank thoroughly with steam or other approved method to sufficiently remove all explosive gas.

INSTALLATION

Fuel Tank - Exploded View:

1. Position fuel tank and install the three attaching bolts and brackets.
2. Torque the attaching bolts to 16-22 lb. ft. (22-30 N-m).
3. Install the fuel tank mounting strap. Torque mounting bolt to 32-45 lb. ft. (43-61 N-m).
4. Install the two parking brake cables retaining brackets to the chassis.
5. Install the fuel tank filler neck hose to the fuel tank filler neck assembly and secure with a clamp.
6. Install the three vapor hoses to the fuel tank filler neck assembly and secure with clamps.
7. Install fuel tank drain plug and torque to 9-13 lb. ft. (12-18 N-m).
8. Install the supply and return fuel hoses to the sending unit and secure with clamps.
9. Install the sending unit access cover with four attaching screws.
10. Reconnect the sending unit electrical connector.
11. Install the rear seat cushion.
12. Connect negative battery cable.
13. Fill tank with fuel and check for leaks.