Fuel Tank: Service and Repair

Fuel Tank And Mounting:

REMOVE/DISCONNECT
1. Negative battery terminal.
2. Relieve fuel system pressure. Refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Block front wheels.
4. Raise rear of the vehicle so that the bottom of rear bumper is 71 cm (28") above ground.
5. Loosen fuel filler neck connecting tube clamp at fuel tank.
6. Wrap a shop towel around 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 filler neck check-ball into tank.
8. Position a siphon hose into fuel tank through fuel filler opening. Place other end into an approved container with the capacity to hold the fuel in the tank. Siphon fuel.
9. Raise vehicle to gain access to 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. Tail pipe hanger attaching bolt.
11. Muffler hanger attaching bolts (2) and muffler hanger.
12. Loosen converter hanger attaching nuts (2).
13. Heat shield attaching screws (2). Note the position of heat shield for installation.
14. Support exhaust and move heat shield to gain access to right side fuel tank retaining strap attaching bolts (2).
15. 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. Quick-connect fittings at inlet side of in-line fuel filter, and fuel return line fitting near 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 plastic tabs of the male end connector of fuel filter, then pull connection apart. Support fuel feed line and filter.
c. Repeat for fuel return line fitting.

17. Fuel level meter electrical connector.
18. Fuel vapor hose at the fuel tank.
19. 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 retaining strap, as this may damage the straps.

21. Place fuel tank in a suitable work area.

INSTALL/CONNECT
1. With the aid of an assistant, position and support fuel tank. Install fuel tank retaining straps (2) and attaching bolts (4). Tighten retaining strap bolts to 24 Nm (18 lb.ft.).
2. Vent hose.
3. Vapor hose.
4. 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 new fuel filter is nicked, scratched or damaged during installation, it must be replaced.

5. Quick-connect fitting at inlet side of in-line fuel filter, and return line fitting near in-line fuel filter.
a. Apply a few drops of clean engine oil to male connector tube ends.
b. Push connectors together to cause 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 fuel level meter electrical connector and fuel return line under in-line fuel filter bracket.
7. In-line fuel filter and new body clips (2).
8. Filler neck and connecting tube and clamp.
9. Position heat shield as noted during removal.
10. Heat shield attaching screws (2). Tighten to 25 Nm (18 lb.ft.)
11. Tighten converter hanger attaching nuts (2) to 27 Nm (20 lb.ft.).
12. Muffler hanger and muffler hanger attaching bolts (2). Tighten bolt to 25 Nm (18 lb.ft.).
13. Tail pipe hanger attaching bolt. Tighten to 27 Nm (20 lb.ft.).
14. Lower vehicle.
15. Add fuel and install fuel filler cap.
16. Negative battery terminal.
INSPECT
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.