Fuel Tank: Service and Repair

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

Removal

1. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe. For some models, the use of a small diameter hose might be necessary because of special components inside the fuel filler pipe. Use a 1/4-inch fuel hose. Vehicles with fuel injected engines have reservoirs inside the fuel tank to maintain fuel near the fuel pick-up during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. This situation can be overcome with a few repeated attempts using different hose orientations.

2. Disconnect fuel hoses and tubes.

NOTE: On vehicles equipped with CFI or EFI engines, the plastic fuel tube connections are on top of the fuel tank and are inaccessible. In these cases, the fuel lines must be disconnected with the tank partially removed from the vehicle.

3. On vehicles equipped with a metal retainer which fastens the filler pipe to the fuel tank, remove the screw attaching the retainer to the fuel tank flange.

4. Disconnect electrical hook-up to the fuel tank sender unit. On some vehicles the electrical connection is inaccessible on top of the tank and no intermediate connection point is provided. In these cases, the electrical connector must be disconnected from the fuel sender with the tank partially removed from the vehicle.

5. Place a safety support under the tank and remove the bolts or nuts from one end of the fuel tank straps. The straps are hinged at one end. Remove the bolts from the unhinged end and swing the straps out of the way. The fuel tank shield attached to the straps, if so equipped should be left in place, if possible, to prevent it from being misplaced or installed incorrectly.

6. Partially remove the tank and disconnect the fuel lines and electrical connector from the fuel gauge sender.

7. Remove tank from the vehicle.

Installation

1. Before proceeding, check the following items:
a. Leak check the sender unit.
b. Be sure fuel vapor separator valve is installed completely on the tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the tank is installed.
d. Replace or reinstall all body mounted fuel tank shields.

2. Place the fuel tank in its proper position in the vehicle. For most models, lubricate the fuel filler pipe with water base tire mounting lubricant. Install the tank onto the filler pipe then bring the tank into final position.

3. Bring fuel tank straps around the tank and start the attaching nut or bolt. Align tank with the straps.

CAUTION: Be certain that strap mounted fuel tank shields are installed with the straps and are positioned correctly on the tank.

4. Check the hoses and wiring mounted on the tank top to be sure they are correctly routed and will not be pinched between the tank and body.

5. Tighten the fuel tank strap attaching nuts or bolts to specification.

6. Reconnect the fuel hoses and lines which were disconnected. Be certain that the fuel supply, fuel return, (if present) and vapor vent connections are made correctly. Trace the various lines to the engine and refer to the applicable system illustrations to be sure the proper lines are connected.

7. Reconnect electrical connections.

8. Replace fuel drained from the tank.

9. Check all connections for leaks.