Fuel Tank Unit: Service and Repair

REMOVAL
1. Drain and remove fuel tank. Refer to Fuel Tank Removal/Installation.
2. Thoroughly clean area around tank module at top of tank.

Fig. 46 Locknut Removal/Installation (Typical):

3. The plastic fuel tank module locknut is threaded onto fuel tank (Fig. 46). Install Special Tool 6856 to locknut and remove locknut. The fuel tank module will spring up when locknut (Fig. 46) is removed.
4. Remove module from fuel tank.

INSTALLATION

CAUTION: Whenever the fuel tank module is serviced, the rubber gasket must be replaced.

1. Thoroughly clean locknut and locknut threads at top of tank.
2. Using new gasket, carefully position fuel tank module into opening in fuel tank.
3. Position locknut over top of fuel tank module. Install locknut finger tight.
4. When looking down at tank from drivers side of tank, the arrow at top of module should be aligned between two marks stamped into tank (approximately 2 o'clock position). The fuel line connectors, roll over valve and fuel gauge electrical connector should all be pointed to drivers side of vehicle. Rotate and align module/tank marks if necessary before tightening locknut. This step must be performed to prevent the module's float from contacting side of fuel tank.
5. Tighten locknut to 24-44 Nm (18-32 ft. lbs.) torque.
6. Install fuel tank. Refer to Fuel Tank Removal/Installation.