Fuel Tank: Service and Repair

Fuel Tank And Components:

REMOVAL

Fuel Pump Harness Connector:

1. Disconnect the fuel pump connector.
2. Start and run the engine until it stalls, then turn the ignition switch to OFF.
3. Disconnect the battery negative terminal.
4. Remove the fuel tank cap.

Drain Plug Location:

5. Drain the fuel.

Return And Vapor Line Connector Locations:

6. Disconnect the return line and vapor hose.

Fuel Filler And Leveling Hose Connections:

7. Detach the fuel filler hose and leveling hose.

Fuel Tank Mounts:

8. Loosen the two self-locking nuts, that hold the tank in position and remove the two tank bands.
CAUTION: Insure that there is something in position to restrain the tank from falling prior to removing the tank bands.
9. Lower the tank, rear end first, far enough to allow access between the vehicle body and the top of the tank. This is to facilitate performing the next two steps.
NOTE: Take special care not to bend the fuel line on the pump or pull loose the electrical wiring.

High Pressure Hose Connection:

10. Disconnect the fuel high pressure line.
CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the line.

Fuel Gauge And Connector Location:

11. Disconnect the fuel gauge unit connector.
12. Remove the fuel tank.


INSTALLATION
1. Confirm that the pad is fully bonded to the fuel tank.
2. Install the fuel tank, by tightening the self-locking nuts to the tank bands, until the rear end of the tank band contacts the body.

Fuel Hose Connection Specifications:

3. Connect the leveling hose, from the tank, approximately 1.6 in. (40mm) onto the filler neck.
4. When connecting the filler hose, the end with the shorter straight pipe should be connected to the tank side.

Vapor Hose Connection Specifications:

5. Connect the vapor hose and return line as shown in the illustration.

High Pressure Hose Connection:

6. Connect the high pressure hose.
CAUTION: When tightening the flare nut, be careful not to bend or twist the line.
7. Connect the electrical fuel pump and fuel gauge unit connector.
8. Tighten the drain plug.