Fuel Tank Assembly

CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off of the hoist.

Remove or Disconnect
1. Negative battery cable.
2. Drain fuel tank. Refer to "Fuel Tank Draining"[1][2]Fuel Tank Draining.
3. Raise vehicle and suitably support.
4. Fuel sender connector.
5. Muffler hanger bolts.
6. Exhaust rubber hangers. Allow exhaust system to rest on rear axle.
7. Hoses from fuel tank sender. Refer to "Quick-Connect Fittings"Fuel Supply Line under Fuel Supply Line.
8. Hoses at tank from filler, vent and vapor pipes.
9. With aid of an assistant, support fuel tank and disconnect the two fuel tank retaining straps.
10. Tank from vehicle.

Inspect
- Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required.
- Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.

Install or Connect
1. Sound insulators.
2. With aid of an assistant, fuel tank to body.
3. Fuel tank retaining straps.
4. Tighten Bolts to 33 Nm (24 lbs. ft.)
5. Hoses to filler, vent and vapor pipes.
6. Nylon fuel feed and return connecting line quick-connect fittings to fuel sender.
7. Exhaust rubber hangers.
8. Tighten muffler hanger bolts to 15 Nm (11 lbs. ft.)
9. Fuel tank sender electrical connector.
10. Lower vehicle.
11. Refill tank.
12. Negative battery cable.

Inspect

- Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.