Fuel Tank Assembly
Fuel Tank Components:
Fuel Tank Insulator, Covertible Only:
Remove or Disconnect:
1. Relieve fuel system pressure
2. Drain fuel tank
3. Remove four filler door bezel attaching screws
4. Remove filler cap
5. Lift fuel tank filler neck housing and disconnect drain hose from nipple
6. Reinstall fuel filler cap to prevent dirt and debris from entering the tank
7. Remove fuel tank filler neck housing
8. Remove fuel sender assembly electrical connector
9. Disconnect fuel feed hose, return hose and vapor hose from sender assembly
10. Remove license plate to gain access for removal of carriage bolts
11. Remove all rear lamps to access outer fascia retainer nuts
12. Remove two carriage bolts securing fascia to impact bar
13. Raise vehicle on hoist
14. Remove spare tire and tire carrier from frame
15. Remove mufflers as an assembly from rear of converters
16. Remove canister splash shield
17. Remove upper body panel supports
18. Remove wheel house liner panels
19. Remove antenna ground strap and clip
20. Disconnect vapor lines from canister
21. Remove vapor canister
Fuel Tank Cables:
22. Remove fuel tank cables from stabilizer shaft supports
23. Remove two attaching screws securing bottom edge of fascia to energy absorber pad
24. Remove marker lamps and spare tire light
25. Remove 4 attaching nuts securing each side of fascia to fascia retainer
26. Remove five attaching nuts securing each side of outer retainer to fascia
27. Remove three impact bar bolts from each side and loosen from impact bar bolts, do not remove
28. Support impact bar and remove front impact bar bolts
29. Remove impact bar and fuel tank assembly
30. Remove fuel tank straps from tank
31. Remove fuel tank from impact bar
32. If tank is being replaced transfer cables, vapor connections and hoses, and fuel sender assembly
Install or Connect:
1. Connect fuel tank to impact bar
2. Connect fuel tank straps to tank and impact bar
3. Tighten tank strap bolts
Torque Value: 15 N-m (11 lb.ft.)
4. Tighten tank strap nuts
Torque Value: 4.5 N-m (40 lb.in.)
5. Install impact bar and tank assembly
6. Tighten eight impact bar bolts
Torque Value: 50 N-m (37 lb.ft.)
7. Tighten outer fascia retainers securing fascia to body
Torque Value: 6 N-m (53 lb.in.)
8. Install and tighten nuts to each side of fascia to fascia retainer
Torque Value: 6 N-m (53 lb.in.)
9. Install two carriage bolts securing fascia to impact bar
10. Connect antenna ground strap and clip
11. Install both rear fender panels
12. Install both inner fender braces at frame
13. Connect hoses to vapor canister
14. Install vapor canister and splash shield
15. Install mufflers as an assembly
16. Install spare tire and carrier holder to frame
17. Lower vehicle
18. Install all rear lamps
19. Install license plate
20. Connect fuel feed, fuel return and vapor hoses to fuel sender
21. Refill fuel tank
22. Connect negative battery cable
23. Drain hose, seal and fuel filler door bezel
Inspect:
Turn ignition switch to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position and check for fuel leaks.