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.

Fuel Tank Removal






1. Fuel should be drained from the fuel tank as completely as possible prior to tank removal. This is accomplished by disconnecting fuel filler pipe from rubber hose and siphoning or pumping fuel out through remaining rubber hose. Vehicles with fuel injected engines have reservoirs inside the fuel tanks to maintain fuel near fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs, and the long fill pipe extension inside the tank, could block siphon tubes or hoses from reaching bottom of fuel tank. This situation can be overcome with a few repeated attempts using different hose orientations.
2. Loosen filler pipe and vent hose clampsat tank and remove hoses from tank.
3. Place a safety support under tank and remove bolts or nuts from one end of fuel tank straps. The straps are hinged at the other end. Remove bolts from unhinged end and swing straps out of the way. The fuel tank shield, if so equipped, should be left in place to prevent it from being misplaced or installed incorrectly.
4. Partially remove tank and disconnect fuel lines and electrical connector from fuel gauge sender/pump assembly, if required.
5. Remove tank from vehicle.

Installation

1. Before proceeding, do the following:
a. Check sender unit for leaks.
b. Ensure fuel vapor separator valve is installed completely on tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after tank is installed. Route lines through clip on tank.
2. Place fuel tank in its proper position in vehicle.
3. Bring fuel tank straps around tank and start attaching nut or bolt. Align tank with straps.
4. Check hoses and wiring mounted on tank top, to ensure they are correctly routed and will not be pinched between tank and body.
5. lighten fuel tank strap attaching bolts to specification.
6. Install fuel filler hoses which connect tuel tank to fuel filler pipe. Install hose clamps and tighten to specification.
7. Replace fuel drained from tank.
8. Check all connections for leaks.