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

1. Fuel should be drained from tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping fuel out through fuel filler pipe. The use of a small diameter hose may be necessary because of special components inside fuel filter pipe. Use a 6.35mm (1/4-inch) fuel hose. A reservoir located inside fuel tank maintains fuel near the fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. This reservoir could block siphon tubes or hoses from reaching the bottom of fuel tank. This problem can be corrected with a few repeated attempts using different hose positions.

2. Raise vehicle.
3. Remove fuel tank shield.
4. Place a safety support under tank. Remove bolts from rear end of fuel tank straps.






5. Partially lower fuel tank. Disconnect pressure line push connect fitting (hairpin type clip) as outlined. Swing straps out of way.
6. Disconnect RH and LH vapor tubes from vapor valve assemblies.
7. Remove ground strap retaining screw at filler neck.
8. Remove electrical connectors from fuel gauge sender.
9. Remove tank from vehicle.

Installation

1. Before proceeding check the following items:
a. Leak-check sender unit.
b. Ensure fuel vapor separator valves are installed completely on tank top.
c. Replace or install all body mounted fuel tank shields if removed.
2. Raise tank to vehicle. Make all required fuel line, fuel return line, vapor vent and electrical connections which wilt be inaccessible after tank is installed.
3. Place fuel tank in its proper position in vehicle.
4. Bring fuel tank straps around tank and start the attaching bolts. Align tank with straps.

CAUTION: Ensure lower fuel tank shields are installed with the straps and are positioned correctly on the tank.

5. Check hoses and wiring mounted on tank top to ensure they are correctly routed and will not be pinched between tank and body.
6. Tighten fuel tank strap attaching bolts to specification.
7. Install fuel tank shield.