Vehicles Equipped With 17 Gallon Fuel Tank
INSPECTION1. Raise and support vehicle.
2. Remove heat shield from fuel tank. Refer to Figure 1.
NOTE:
Signs of fuel leakage (witness marks) are often indicated by a dry stained area that is created after the leaking fuel has evaporated.
3. Using a shop light, inspect for signs of fuel leakage (witness marks) on sides of the fuel tank. See Figure 2.
^ If there are no signs of fuel leakage (witness marks), no service action is required. Reinstall heat shield and return vehicle to customer.
^ If the fuel tank shows signs of fuel leakage, proceed to "Fuel Tank Removal and Leak Verification.
FUEL TANK REMOVAL AND LEAK VERIFICATION
1. Lower vehicle.
WARNING
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.
2. Relieve fuel system pressure as follows:
^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge.
^ Slowly open manual valve on EFI/CFI fuel pressure gauge to relive fuel pressure.
^ Remove fuel pressure gauge and reinstall schrader valve.
3. Completely drain tank.
4. Raise and support vehicle.
5. Position adjustable jack under fuel tank directly between fuel tank straps.
6. Remove fuel tank straps. See Figure 3.
7. Mark driveshaft-to-driveshaft rear axle companion flange so it can be installed in it's original position.
CAUTION
U-joint bearing caps must be secured to the U-joint or possible damage to the bearing cap and/or the needle bearings can occur.
8. Disconnect driveshaft from rear axle companion flange. Using tape, secure bearing caps to U-joint.
9. Using a length of mechanics wire, secure rear of driveshaft away from fuel tank.
10. Disconnect filler hose from fuel tank.
11. Slightly lower fuel tank.
12. Disconnect the following components:
^ Fuel supply and return lines from fuel pump/sender assembly.
^ Electrical connector from fuel pump/sender assembly.
^ Fuel vapor hose from fuel tank vapor valve.
13. Lower fuel tank from vehicle.
14. Place fuel tank on suitable work table.
15. Inspect top of fuel tank for signs of fuel leakage (witness marks) and cracks.
^ GROMMET LEAKS: If leak is coming from any tank grommets, obtain "Grommet & Seal Kit # E89Z-9B210-CA. Install new vapor valve grommet and new fuel filler neck grommet. Refer to Figure 4.
^ CRACKED LEAKS: If fuel tank is cracked, call Recall Hotline at 1-800-325-5621 to order a new fuel tank kit. Transfer fuel pump/sender, vapor valve and filler hose to new fuel tank. Use supplied fuel pump/sender seal. Tighten fuel pump/sender lock ring to 81-115 Nm (60-85 lb-ft). New vapor valve grommet and fuel filler neck grommet are already installed in new fuel tank.
FUEL TANK INSTALLATION
1. Secure fuel tank to adjustable jack. Make sure jack will not interfere with fuel tank strap installation.
2. Raise fuel tank to close to installed position.
3. Connect the following components:
^ Fuel supply and return lines to fuel pump/sender assembly.
^ Electrical connector to fuel pump/sender assembly.
^ Fuel vapor hose to fuel tank vapor valve.
CAUTION:
Make sure all fuel lines, vapor hoses, and electrical wiring are properly routed.
4. Raise fuel tank to its installed position.
5. Connect filler neck hose to fuel tank. Tighten clamp to 3-4 Nm (25-35 lb-in).
6. Install fuel tank straps. Tighten bolts to 47-61 Nm (35-45 lb-ft).
7. Remove adjustable jack.
8. Install fuel tank heat shield. Tighten bolts and nuts to 6-8 Nm (53-70) lb-in). Tighten screw to 3-6 Nm (26-50 lb-in).
9. Connect driveshaft to rear axle companion flange. Tighten retainers as follows:
^ If equipped with U-bolt axle companion flange, tighten nuts to 11-20 Nm (8-15 ft-lb).
^ If equipped with circular flange axle attachment, tighten bolts to 95-129 Nm (70-95 ft-lb).
10. Lower vehicle.
11. Fill fuel tank.
12. Start engine and check fuel system for leaks.