Fuel Tank: Service and Repair

WARNING: Explosion and fire hazard. Observe the following precautions when working on the fuel tank.

^ Be sure area is well ventilated.
^ Do not smoke or light any cigarettes where odor of fuel vapor is present.
^ Disconnect battery and do not create any sparks or flames where odor of fuel vapor is present.
^ An empty fuel tank contains an explosive mix of fuel vapors and air. If tank repair is necessary that involves any welding or soldering, clean inside of tank with solution of detergent and water and then use steam to displace any residual vapors that may remain.

FUEL TANK REMOVAL AND INSTALLATION

Fuel Tank Assembly:

1. Relieve fuel system pressure by starting engine with fuel pump relay (circuit open relay) disconnected and let run until engine dies. Then slowly and carefully remove hose on outlet side of fuel filter. Cover with a clean rag while removing hose, to avoid spraying fuel in your face.

2. Remove the #2 rear seat and lift up the floor covering.

3. Remove access cover on floor panel to expose the fuel pump/gauge unit assembly.

4. Disconnect fuel hoses.

5. Remove fuel filler cap.

6. Lift vehicle and support on jack stands.

7. Remove fuel tank drain plug and drain fuel into a suitable container, then re-install plug and tighten.

8. Disconnect fuel gauge/pump electrical connector at side of tank.

9. Disconnect fuel filler hose, and remaining fuel and vapor hoses.


10. Remove fuel tank retention straps and lower tank out of vehicle

Install in reverse order.