Fuel Tank: Service and Repair

Tools Required:
Fuel Tank Sender Wrench T74P-9275-A
Rotunda Fuel Storage Tanker 034-00002
Rotunda Adapter Hose 034-00011

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 fuel tank as completely as possible pribr to fuel tank removal. This is accomplished by siphoning or pumping fuel out the fuel tank filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. Vehicles with fuel injected engines have reservoirs inside the fuel tanks to maintain fuel near fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs, and the long fuel tank to filler pipe hose (9047) extension inside the fuel tank, could block siphon tubes or hoses from reaching bottom of fuel tank. This situation may require a few repeated attempts using different hose orientations.
2. Loosen fuel tank to filler pipe hose and fuel tank vent tube (9A228) clamps at fuel tank and remove hoses from fuel tank.
3. Place a safety support under fuel tank and remove bolts from rear end of fuel tank support straps (9092). The fuel tank support straps are hinged at the front end and will swing out of the way.
4. Partially remove fuel tank and disconnect fuel tubes and electrical connector from fuel tank sending unit I fuel pump assembly. Refer to Push Connect Fitting Removal.
5. Remove fuel tank from vehicle.

INSTALLATION

NOTE: If fuel tank sending unit/fuel pump assembly has been removed, the 0-ring seal must be replaced.

1. Before proceeding, do the following:
a. Check fuel tank sending unit unit for leaks. If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A.
b. Ensure fuel vapor valve (9B593) is installed completely on fuel tank top.
C. Make all required fuel and vapor return tube, fuel tank vent tube and electrical connections which will be inaccessible after fuel tank is installed. Route lines through clip on fuel tank.
2. Place fuel tank in its proper position in vehicle.

CAUTION: Make sure that fuel tank shields are installed with the straps and are positioned correctly on the tank.

3. Bring fuel tank support straps around fuel tank and start retaining bolt. Align fuel tank as far forward in vehicle as possible while securing retaining bolts.
4. Check hoses and wiring mounted on fuel tank tQp, to ensure they are correctly routed and will not be pinched between fuel tank and body.
5. Tighten fuel tank support strap retaining bolts to 29-41 Nm (22-30 lb-ft).
6. Install fuel tank to filler pipe hose which connects fuel tank to fuel tank filler pipe. install hose clamps and tighten to 2.7-3.7 Nm (24-32 lb-in).
7. Replace fuel drained from fuel tank.
8. Check all connections for leaks.