Fuel Tank: Service and Repair

WARNING: Explosion and fire hazard. Observe the following precautions when working on the fuel tank.

^ Be sure area is well ventilated.
^ Always relieve fuel system pressure before disconnecting fuel lines.
^ Do not smoke or light any cigarettes where odor of fuel vapor is present.
^ Disconnect battery and do not create any sparks or flames where odor of fuel vapor is present.
^ An empty fuel tank contains an explosive mix of fuel vapors and air. If tank repair is necessary that involves any welding or soldering, clean inside of tank with solution of detergent and water and then use steam to displace any residual vapors that may remain.

1. Relieve fuel system pressure by starting engine with fuel pump relay (circuit open relay) disconnected and let run until engine dies, then slowly and carefully remove hose on outlet side of fuel filter. Cover with a clean rag while removing hose, to avoid spraying fuel in your face.

Removing Rear Seat Cushion:

2. Remove the rear seat.

Fuel Pump Harness Connector And Access Panel:

3. Disconnect fuel pump electrical connectors.

4. Remove access panel and pull wiring with connectors and rubber grommet through hole in panel.

Fuel Tank Assembly:

5. Drain fuel from the fuel tank.

6. Remove the fuel pump connectors.

7. Remove the fuel hoses.

8. Remove steering angle transfer shaft.

9. Remove rear steering cross member

10. Remove the evaporative hoses.

11. Remove the fuel filler hose.

12. Remove the breather hose.

13. Remove the fuel tank strap.

14. Remove the fuel tank.

15. Install in the reverse order.