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

Fuel System:

1. Relieve the fuel pressure.
2. Disconnect the battery ground cable.
3. Drain the fuel from the fuel tank.
4. Raise and support the vehicle.

Filler Neck Clamp:

5. Loosen the hose clamp and remove the fuel tank to filler pipe hose.

Filler Pipe:

6. Loosen the overflow tube clamp and remove the fuel tube hose.
7. Loosen the fuel supply tube clamp and remove the fuel supply tube.
8. Loosen the fuel return tube clamp and remove the fuel return tube.
9. Loosen the two fuel tank vent tube clamps and remove the fuel tank vent tubes.
10. Disconnect the fuel pump electrical connector from the body harness mating connector.

Fuel Tank Heat Shield:

11. Remove the four nuts on the fuel tank heat shield.
12. Remove the one nut on the fuel tank shield.

Fuel Tank And Related Components:

13. Support the fuel tank and remove the center fuel tank support strap bolt.
14. Remove the right hand fuel tank support strap bolt.

Fuel Tank Shield:

15. Remove the fuel tank shield.
16. Remove the left side fuel tank support strap bolt.

Fuel Tank:

17. Remove the fuel tank.

WARNING: Before repairing, clean the fuel tank thoroughly with steam or other approved method to sufficiently remove all explosive gas.

NOTE: Check the fuel tank for cracks and corrosion. If any defect is found, repair or replace the fuel tank.

INSTALLATION

NOTE: Do not apply excessive force to the bottom of fuel tank with the jack. This could bend the fuel pump bracket inside the fuel tank.

To install, reverse the removal procedure. Check the fuel tank for leaks.