Fuel Tank: Service and Repair

WARNING: This procedure involves working with parts associated with gasoline delivery. Even though the gasoline may be drained from the parts, some gasoline and/or gasoline vapors may remain. Do not smoke or bring parts into an area where an open flame or spark could ignite the gasoline or gasoline vapors. Serious bodily injury may result if gasoline or vapors ignite. When service procedures involve gasoline suitable fire extinguishing equipment should be available in the area.





REMOVAL

Electric Fuel Pump And Fuel Gauge Connectors:

1. 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.

Fuel Tank Drain Plug:

5. Drain the fuel into an approved safety container.

High Pressure Fuel Line Connector:

6. Disconnect the fuel high pressure line.

CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the line.

Fuel Return And Vapor Line Connectors:

7. Disconnect the return line and vapor hose.

Fill And Leveling Hose Connections:

8. Detach the fuel filler hose and leveling hose.

Fuel Tank Mounts:

9. Position a jack or support under the fuel tank.
10. Loosen the two self-locking nuts, that hold the tank in position and remove the two tank bands.
11. Lower and remove the fuel tank.

INSTALLATION
1. Confirm that the pad is fully bonded to the fuel tank.
2. Position the tank on a jack or support, raise tank into place.
3. Install the fuel tank, by tightening the self-locking nuts to the tank bands, until the rear end of the tank band contacts the body.

Fuel Hose Connection Specifications:

4. Connect the leveling hose, from the tank, approximately 1.6 in. (40mm) onto the filler neck.
5. When connecting the filler hose, the end with the shorter straight pipe should be connected to the tank side.

Vapor Hose Connection Specifications:

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

High Pressure Hose Connection:

7. Connect the high pressure hose.

CAUTION: When tightening the flare nut, be careful not to bend or twist the line.

8. Connect the electrical fuel pump and fuel gauge unit connector.
9. Tighten the drain plug.