Fuel Tank: Service and Repair

All wheel drive models require the drive shaft be removed prior to fuel tank removal. Refer to Axles, Driveshafts Replacement procedures in TRANSMISSIONS CLUTCHES DIFFERENTIALS AXLES AND DRIVE SHAFTS

Fuel Tank And Related Parts (AWD):

REMOVAL

Main Fuel Tank Fuel Gauge Connector (AWD):

Sub Fuel Tank Gauge Connector (AWD):

1. Remove rear seat. Remove access covers and disconnect the fuel pump and fuel gauge connectors.
2. Start and run the engine until it stalls, then turn the ignition switch to OFF.
3. Disconnect the battery negative terminal.
4. Remove the fuel tank cap.
5. Drain the fuel.

Fuel Tank Pressure Control (Two-way) Valve:

6. Disconnect the fuel high pressure line.
CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the line.
7. Disconnect the return line and vapor hose.
8. Detach the fuel filler hose and vapor hose.

Filler And Vapor Hose Connection:

CAUTION: Insure that there is something in position to
restrain the tank from falling prior to removing the tank mounting bolts.
9. Remove the bolts that hold the tank in position.
10. Remove the fuel tank.

INSTALLATION
1. Install and bolt into place the fuel tank.
2. Connect the leveling hose, from the tank, approximately 1.6 in. (40mm) onto the filler neck.

Filler And Vapor Hose Connection:

3. Connect the filler hose.

Vapor Hose Connection Specifications:

4. Connect the vapor hose and return line as shown in the illustration.

High Pressure Hose Connection:

5. Connect the high pressure hose.
CAUTION: When tightening the flare nut, be careful not to bend or twist the line.

Torque value:
22 - 29 ft.lbs. (30 - 40 Nm)

6. Connect the electrical fuel pump and fuel gauge unit connector.
7. Tighten the drain plug.

Torque value:
4 ft.lbs. (13 Nm)

8. Connect the negative battery terminal.