Fuel Tank: Service and Repair

Fuel Tank Mounting:

Fuel Tank Insulator (Convertible Only):

Fuel Tank Cables:

REMOVAL:
1. Relieve the fuel system pressure. See Fuel System Pressure Relief.
2. Use a hand operated pump and hose inserted through the filler neck, to drain as much fuel from the tank as possible.
3. Remove the filler door bezel attaching screws and bezel.
4. Remove the fuel filler cap.
5. Lift the fuel tank filler neck housing and disconnect the drain hose from the nipple.

NOTE: Clean all fuel connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.

6. Remove the fuel tank filler neck housing.
7. Disconnect the fuel level meter assembly electrical connector.
8. Disconnect and plug fuel feed hose, return hose, and vapor hose.
9. Remove sender assembly attaching screws and remove sender from tank.
10. Remove the license plate and all rear lights and remove the carriage bolts and nuts securing the fascia to the impact bar.
11. Remove fascia and raise the vehicle on a hoist.
12. Remove the spare tire and tire carrier from the frame.
13. With the aid of an assistant, remove exhaust system hangers and remove the mufflers and exhaust pipes as an assembly rear of the catalytic converters.
14. Remove vapor canister splash shield.
15 Remove upper body panel supports and wheel housing liner panels.
16. Remove the antenna ground strap and clip at the frame and at the antenna base.
17. Disconnect the fuel vapor hose from vapor canister and tank and remove canister.
18. Remove the fuel tank cable attaching nuts and both fuel tank cables from the anti-sway bar supports.
19. Remove the attaching screws securing the bottom edge of the fascia to energy absorber pad.
20. Remove side marker lamps and spare tire light.
21. Remove the attaching nuts securing each side of the fascia to fascia retainer.
22. Remove the nuts securing each side of outer fascia to retainer.
23. Remove rear impact bar bolts (3 on each side) and loosen front impact bar bolts (1 on each side, do not remove).
24. With the aid of an assistant, support impact bar and remove front impact bar bolts and remove impact bar and fuel tank assembly.
25 Remove fuel tank straps from tank.
26. Remove fuel tank from impact bar.
27. If the fuel tank is being replaced, transfer:
- Cables.
- Vapor connections and hoses
- Fuel level meter assembly.

FUEL TANK INSTALLATION:
1. Reverse the removal procedure.
2. Tighten:
- The front fuel tank retaining strap bolts to 15 Nm (11 lb.ft).
- The rear fuel tank retaining strap nuts to 4.5 Nm (40 lb.in).
- Fuel tank cable attaching nuts to 20 Nm (15 lb.ft).
3. Connect the negative battery cable.
4. Turn the ignition switch ON for two seconds, then turn it OFF for ten seconds. Again turn the ignition switch ON and check for fuel leaks.