FUEL TANK

Tank Assembly

REMOVAL & INSTALLATION

1. Properly relieve the fuel system pressure as outlined earlier in this section.
2. Drain the fuel from the fuel tank into an approved container.
3. Raise the vehicle and support safely.
4. For 1995–98 AWD vehicles, perform the following:
   1. Remove the driveshaft.
   2. Detach the heated oxygen sensor electrical connector.
   3. Remove the center exhaust pipe.
   4. Unfasten the retainers, then remove the fuel tank protector.
5. Disconnect the return hose, high pressure hose and vapor hoses from the fuel pump.
6. Disconnect the electrical connectors at the pump/sending unit.

   CAUTION
   Cover all fuel hose connections with a shop towel, prior to disconnecting, to prevent splash of fuel that could be caused by residual pressure remaining in the fuel line.

7. Disconnect the filler and vent hoses.
8. Place a transmission jack under the center of the fuel tank and apply a slight upward pressure. Remove the fuel tank strap retaining nut or tank retaining nuts, as applicable.
9. Lower the tank slightly and disconnect any remaining electrical or hose connectors at the fuel tank.
10. Remove the fuel tank from the vehicle.

    Fig. 1: Exploded view of the fuel tank and related components — 1990–94 Front Wheel Drive (FWD) vehicle

    Fig. 2: Fuel tank and related components — 1990–94 All Wheel Drive (AWD) vehicle

    Fig. 3: Exploded view of the fuel tank and related components — 1995–98 FWD

    Fig. 4: You have to remove some exhaust components for access to the fuel tank on 1995–98 AWD vehicles

    To install:

11. Install the fuel tank onto the transmission jack. Raise the tank in position under the vehicle. Leave enough clearance to attach the electrical and hose connections to the top of the fuel pump.
12. Attach all connections to the top of the tank.
13. Raise the tank completely and position the retainer straps around the fuel tank, if equipped. Install new fuel tank self-locking nuts and tighten.
14. Connect the return hose and high pressure hoses.
15. Install the vapor hose and the filler hose. Install the filler hose retainer screws to the fender, if removed.
16. For 1995–98 AWD vehicles, perform the following:
    1. Install the fuel tank protector and install the retainers.
    2. Install the center exhaust pipe.
    3. Attach the heated oxygen sensor electrical connector.
    4. Install the driveshaft.
17. Carefully lower the vehicle and pour the drained fuel back into the gas tank.
18. Connect the negative battery cable. Check the fuel pump for proper pressure and inspect the entire system for leaks.