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 - Exploded View:

REMOVAL:

1. Raise vehicle to gain access to the fuel tank.
2. Drain fuel from tank into a suitable container utilizing either the fuel pump to pump the fuel or a siphon hose.

3. Remove filler cap.
4. Disconnect fuel pump and gauge sending unit wiring harnesses.
5. Disconnect filler neck/overflow pipe from tank.
6. Disconnect fuel supply and return hoses from tank pipes.
7. Remove filler pipe protective shield.
8. Cover openings in tank to prevent dirt from entering the tank.
9. Support the fuel tank with a transmission jack. DO NOT dent the bottom of the tank.
10. Remove the fuel tank mount bolts and tank protectors.
11. Lower jack and tank from underside of vehicle.

INSTALLATION:

1. If any hoses or accessories are removed from the tank, make sure and use new gaskets when reinstalling these items.
2. Position tank on transmission jack and align tank under rear of vehicle.
3. Jack tank into place. DO NOT dent fuel tank.
4. Place tank protectors in the proper places and install the mount bolts.
5. Ensure proper protector installation and torque mount bolts to 25 ft.lbs (34 Nm).
6. Connect fuel supply/return hoses to tank pipes.

Installing Fuel Hoses:

7. Torque fuel supply hose fitting to 22 ft.lbs. (30 N-m).
8. Install new gasket and connect filler neck/overflow pipe to tank. Torque screws to 30 in.lbs. (3.4 N-m).
9. Connect fuel pump and gauge sending unit wiring harnesses.
10. Install filler cap and protective shield.
11. Lower vehicle and fill tank with gasoline.
12. Start engine and check for fuel leaks.