Fuel Tank Removal and Installation
FUEL TANK REPLACEMENTCAUTION: Before attempting to service the fuel system, take the following precautions:
^ Disconnect the battery negative (-) cable.
^ Place "No Smoking" signs near the work area.
^ Be sure to have a dry chemical (Class B) fire extinguisher close to the work area.
^ Wear safety glasses.
^ Siphon or pump fuel into an explosion-proof container to prevent the possibility of an explosion or fire.
Clean
- Before removing fuel system parts, clean them with a spray-type engine cleaner (AC-Delco X-30A or equivalent). Follow the cleaner instructions. Do not soak fuel system parts in liquid cleaning solvent.
Remove or Disconnect
^ Follow the "Fuel System Pressure Relief" procedure. Fuel Pressure Release
1. Battery negative (-) cable.
2. Fuel filler cap.
^ Follow the "Fuel Tank Draining" procedure. Fuel Tank Draining Procedure
^ Raise and suitably support vehicle.
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 felling off the hoist.
3. Exhaust pipe from catalytic converter.
4. Fuel filler neck hose from fuel tank (loosen clamp).
5. Fuel overflow pipe hose from the fuel tank (loosen clamp).
6. Fuel gage, sending unit electrical connector.
7. Fuel pump electrical connector.
8. Fuel vapor hose from the fuel tank pipe (spread clamp).
9. Fuel pump supply hose (loosen screw-type fitting) from pipe.
10. Fuel pump return hose (spread clamp).
^ Support fuel tank using a transaxle jack.
11. Six fuel tank mounting bolts.
^ Lower fuel tank.
Inspect
^ Sealing surfaces of the hose and pipe fittings.
^ Tank exterior for damage. Replace as necessary.
Install or Connect
^ Raise fuel tank using a transaxle jack.
1. Fuel tank mounting bolts.
Tighten Fuel tank mounting bolts to 19 N.m (14 lb.ft.).
^ Remove transaxle jack.
2. Fuel pump return hose (spread clamp).
3. Fuel pump supply hose (tighten screw-type fitting).
Tighten Fuel pump supply hose fitting nut to 34 N.m (25 lb.ft.).
4. Fuel vapor hose (spread clamp).
5. Fuel pump electrical connector.
6. Fuel gage, sending unit electrical connector.
7. Fuel overflow pipe hose (tighten clamp).
8. Exhaust pipe to catalytic converter.
9. Fuel filler neck hose (tighten clamp).
^ Lower vehicle.
^ Refill the fuel tank.
10. Fuel filler cap.
11. Battery negative (-) cable.
Inspect
^ Start engine and check for leaks.