Fuel Tank: Service and Repair

Fuel Tank R&R:

WARNING: Explosion and fire hazard. Observe these precautions when working on fuel tank:
^ Be sure area is well ventilated.
^ Relieve fuel system pressure before disconnecting lines.
^ Do not smoke where fuel vapor is present.
^ Disconnect battery and do not create sparks or flames where fuel vapor is present.
^ Empty fuel tanks contain an explosive mix of fuel vapors and air. If tank repair involves welding or soldering, clean inside of tank with solution of detergent and water. Use steam to displace any residual vapors.


1. Relieve fuel system pressure.
2. Remove rear seat cushion.
3. Unplug tank gauge unit electrical connector and remove access cover.
4. Disconnect fuel hoses.
5. Lift vehicle and support with jackstands.
6. Drain fuel into suitable container.
7. Remove insulator cover from front of tank.
8. Disconnect remaining hoses and remove tank.
9. Install in reverse order and observe the following:


INSTALLATION NOTE

Fuel Line Installation:

1. Push main and return fuel hoses and evaporative hoses onto fuel tank fittings at least 1.0 in (25 mm).
2. Push fuel filler hose onto fuel tank pipe and filler pipe at least 1.4 in (35 mm).