Fuel Tank: Service and Repair

REMOVAL

Fuel Tank Assembly:

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.
5. Drain the fuel.
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 Assembly:

9. Loosen the two self-locking nuts, that hold the spare tire carrier in place, and remove the tire carrier. Loosen the self locking nuts that hold the fuel tank in position, and using a suitable jack, lower and remove the fuel tank.

INSTALLATION
1. Install the fuel tank, by tightening the self-locking nuts to the tank body, until the rear end of the tank contacts the body.

Fuel Hose Connection Specifications:

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

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.
6. Install the spare tire carrier and tighten the mounting bolts.
7. Connect the electrical fuel pump and fuel gauge unit connector.
8. Tighten the drain plug.
9. Connect the negative battery terminal.