Fuel Tank Assembly

Fuel Tank And Mounting:

REMOVAL

1. Disconnect the negative battery terminal.
2. Relieve fuel system pressure. Refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Block the front wheels.
4. Raise the rear of the vehicle so that the bottom of the rear bumper is 71 cm (28") above ground.
5. Loosen the fuel filler neck connecting tube clamp at the fuel tank.
6. Wrap a shop towel around the fuel filler neck connecting tube and slowly remove fuel filler neck connecting tube from the tank.
7. Using a socket extension (approximately 18" long), push the filler neck check-ball into the tank.
8. Position a siphon hose into the fuel tank through the fuel filler opening. Place the other end into an approved container with the capacity to hold the fuel in the tank. Siphon fuel.
9. Raise the vehicle to gain access to the fuel tank.

WARNING: To help avoid personal injury when the vehicle is on the hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

10. Remove the tail pipe hanger attaching bolt.
11. Remove the muffler hanger attaching bolts (2) and muffler hanger.
12. Loosen the converter hanger attaching nuts (2).
13. Remove the heat shield attaching screws (2). Note the position of the heat shield for installation.
14. Support the exhaust and move the heat shield to gain access to the right side fuel tank retaining strap attaching bolts (2).
15. Remove the in-line fuel filter body clips (2).

CAUTION: If the nylon fuel feed or return lines become kinked or damaged in any way, they must be replaced. DO NOT attempt to repair sections of nylon fuel lines. If damaged, replace with new part.

16. Disconnect the quick-connect fittings at the inlet side of the in-line fuel filter, and fuel return line fitting near the in-line fuel filter.
a. Grasp both ends of one fuel line connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting. Repeat for other fitting. Blow out the quick-connect fittings with compressed air.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Squeeze the plastic tabs of the male end connector of the fuel filter, then pull the connection apart. Support the fuel feed line and filter.
c. Repeat for the fuel return line fitting.

17. Remove the fuel level meter electrical connector.
18. Remove the fuel vapor hose at the fuel tank.
19. Remove the vent hose at the fuel tank.
20. With the aid of an assistant, support the fuel tank and remove the left and right fuel tank retaining straps (2) and fuel tank.

NOTE: DO NOT bend the retaining strap, as this may damage the straps.

21. Place the fuel tank in a suitable work area.

INSTALLATION

1. With the aid of an assistant, position and support the fuel tank. Install the fuel tank retaining straps (2) and attaching bolts (4). Tighten the retaining strap bolts to 24 Nm (18 lb.ft.).
2. Connect the vent hose.
3. Connect the vapor hose.
4. Connect the fuel level meter electrical connector.

WARNING:

a. Before connecting fuel line quick-connect fittings, always apply a few drops of engine oil to the male tube ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the o-rings inside the female connector will swell and may prevent proper reconnection if not lubricated.
b. If the new fuel filter is nicked, scratched or damaged during installation, it must be replaced.

5. Connect the quick-connect fitting at the inlet side of the in-line fuel filter, and the return line fitting near the in-line fuel filter.
a. Apply a few drops of clean engine oil to the male connector tube ends.
b. Push connectors together to cause the retaining tabs/fingers to snap into place.
c. Once installed, pull on both ends of each connection to make sure it is secure.
6. Position the fuel level meter electrical connector and fuel return line under the in-line fuel filter bracket.
7. Install the in-line fuel filter and new body clips (2).
8. Install the filler neck and connecting tube and clamp.
9. Position the heat shield as noted during removal.
10. Install the heat shield attaching screws (2). Tighten to 25 Nm (18 lb.ft.)
11. Tighten the converter hanger attaching nuts (2) to 27 Nm (20 lb.ft.).
12. Install the muffler hanger and muffler hanger attaching bolts (2). Tighten the bolt to 25 Nm (18 lb.ft.).
13. Install the tail pipe hanger attaching bolt. Tighten to 27 Nm (20 lb.ft.).
14. Lower the vehicle.
15. Add fuel and install the fuel filler cap.
16. Connect the negative battery terminal.
17. Turn the ignition switch to the ON position for 2 seconds, then turn to OFF for 5 seconds. Again turn to ON position and check for fuel leaks.