Fuel Tank: Service and Repair

WARNING:
Before attempting to remove the fuel tank, observe the following precautions:
^ Be sure to have a Class B, dry chemical fire extinguisher close to the work area.
^ Wear safety glasses.
^ Siphon or pump fuel into an explosion-proof container to prevent the possibility of explosion or fire.

Fuel Tank And Components:

REMOVAL:

1. Disconnect the negative battery terminal.
2. Remove the following parts from the interior passenger compartment:

Interior Console And Dash Panel:

a. Console boxes
b. LH, lower instrument finish panel
c. Center instrument finish panel
d. Ash recepticle box
e. Ash recepticle retainer
3. Disconnect the fuel pump and fuel gauge sender unit connectors.
4. Remove the two screws and floor service hole cover.

Removing Floor Service Cover:

5. Remove lower engine covers.
6. Remove front luggage under cover.
7. Remove fuel tank protectors.
8. Remove drain plug and drain fuel into a suitable container.
9. Remove parking brake intermediate lever and No.1 center floor crossmember.

Removing No.1 Center Floor Crossmember:

10. Remove the four bolts that secure the A/C hoses to the body.

Disconnecting Air Conditioning Hoses From Body:

11. Remove the six bolts and disconnect the two radiator pipes from the body.

Disconnecting Radiator Pipes From Body:

12. Remove fuel tank heat insulators.

Removing Fuel Tank Heat Insulators:

13. Remove fuel filler cap.
14. Disconnect hoses:

Disconnecting Fuel Hoses And Tube:

a. Fuel inlet hose
b. Fuel breather hose
c. Fuel pump tube
d. Fuel return hose
e. Two EVAP vent hoses
15. Remove the bolt, pin and tank band.

Removing Fuel Tank:

16. Support the fuel tank with a transmission jack. DO NOT dent the bottom of the tank.
17. Remove the No.2 center floor crossmember.
18. Lower the tank from the vehicle.

INSTALLATION:

1. Ensure that tank cushions (pads) are correctly positioned on tank topside. Use adhesive to hold them in place, if necessary.

Fuel Tank Cushions (Pads):

2. Position tank on transmission jack and align tank under rear of vehicle.
3. Jack tank into place. DO NOT dent fuel tank.
4. Install the No.2 center floor crossmember. Torque the bolts to 22 ft.lbs. (29 N-m).
5. Install fuel tank band with pin and bolt. Torque the bolt to 10 ft.lbs. (14 N-m).
6. Connect hoses:
a. Fuel inlet hose
b. Fuel breather hose
c. Fuel pump tube
d. Fuel return hose
e. Two EVAP vent hoses
7. Install radiator pipes to body with six bolts.
8. Install A/C hose clamps to body.
9. Install parking brake intermediate lever and No.1 center floor crossmember.
10. Connect fuel pump and fuel gauge sender unit connectors.
11. Install the floor service cover.
12. Install the following interior parts:
a. Console boxes
b. LH, lower instrument finish panel
c. Center instrument finish panel
d. Ash recepticle box
e. Ash recepticle retainer
13. Install drain plug. Torque the plug to 9 ft.lbs. (13 N-m).
14. Install fuel tank heat insulators.
15. Install lower engine covers.
16. Install fuel tank protectors.
17. Install front luggage under cover.
18. Connect negative battery terminal.
19. Lower vehicle, fill tank with gasoline and install filler cap.
20. Start engine and check for fuel leaks.