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. Drain fuel from the fuel tank.
2. Raise vehicle on hoist.
3. Remove the exhaust system as required.

NOTE: The nylon fuel tube connections are on top of the fuel tank and are inaccessible. They must be disconnected with the fuel tank partially removed from the vehicle.

4. Disconnect fuel tank to filler pipe hose and fuel tank vent tubes connecting the fuel tank filler pipe to tank. Disconnect one end of the fuel tank vent tube at the rear over the driveshaft.
5. Place a safety support under the fuel tank. Remove the bolts from the fuel tank support straps. Take care not to deform the fuel tank, fuel tank support or fuel tank support straps to avoid affecting fuel tank capacity and/or fuel pick-up.
6. Partially remove the fuel tank and disconnect the fuel lines and electrical connector from the fuel gauge sender, if required.
7. Remove fuel tank from the vehicle.

Fuel Tank View:

INSTALLATION

1. Before proceeding, check the following items:
a. Ensure fuel vapor separator valve is installed completely on the fuel tank top.
b. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the fuel tank is installed.
c. Replace or install body mounted fuel tank heat shield.
2. Check the hoses and wiring mounted on the fuel tank top to ensure they are correctly routed and will not be pinched between the fuel tank and body or driveshaft.
3. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel tank filler pipe and the two vent hoses with water based tire mounting lubricant. Install the fuel tank onto the fuel tank to filler pipe hose then bring the fuel tank into final position.
4. Bring fuel tank support straps around the fuel tank and start the retaining nut or bolt. Align fuel tank with the fuel tank support straps and driveshaft.

CAUTION: Make sure the fuel tank vent tube is positioned above the vent retainer and not contacting the driveshaft.

5. Tighten the fuel tank support straps retaining nuts or bolts to 29-41 Nm (22-30 lb ft).
6. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel return (if present) and vapor vent connections are made correctly. Trace the various lines to the engine to ensure the proper lines are connected.
7. Install exhaust system.

CAUTION: Ensure that fuel tank heat shields are installed and are positioned correctly.

8. Lower vehicle.
9. Replace fuel drained from the fuel tank.
10. Check all connections for leaks.