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.

Fuel Tank Assembly:

1. 1. Relieve fuel system pressure by starting engine with fuel pump relay (circuit open relay) or fuel pump electrical connector disconnected. Let run until engine dies. Carefully remove hose on outlet side of fuel filter. To avoid spraying fuel, cover with a clean rag while removing hose. Fuel system pressure can also be relieved by carefully loosening cold start valve banjo bolt.
2. Open trunk lid and remove floor mat.
3. Remove CD changer and amplifier if equipped.

Fuel Pump Access Panel:

4. Remove fuel pump access cover.

Fuel Tank Connections (Electrical, Fuel And vapor):

5. Disconnect electrical connector and fuel and vapor hoses.

Support W/Jackstands Under Side Sills:

6. Lift vehicle and support on jackstands at side sills just in front of the rear wheels.

Rear Crossmember And Suspension Assembly:

7. Remove rear crossmember.
a. Disconnect upper and lower trailing links from inboard mounts.
b. Unbolt lower end of rear shock absorbers from wheel hub assemblies.

Rear Differential And Crossmember Assembly:

c. Disconnect rear parking brake cables from front main cable and remove retaining brackets so cables are free of body.
d. Remove driveshaft.
e. Disconnect rear brake fluid line at common junction block and relocate as necessary to clear differential/crossmember assembly during removal and installation.
f. For ABS equipped vehicles, disconnect wheel sensor electrical connectors and remove harness mounting brackets as necessary.
g. Make sure all hoses, lines, cables, and electrical harnesses attached to the body are free and clear of the differential/crossmember assembly.
h. Support center of assembly under differential housing with suitable jack.
i. Unbolt crossmember from body and carefully lower entire assembly out of car with differential, wheel hub and suspension attached.
8. Drain fuel into suitable container for storage.

Fuel Tank/Hose Connections:

9. Disconnect fuel filler and breather hose.

10. Support tank, remove retaining bracket, and lower tank from vehicle.

11. Install in reverse order.

Rear End Tightening Specifications:

12. Tighten bolts and nuts to specifications (see illustration).