REMOVAL & INSTALLATION
Before disconnecting any fuel line, relieve the pressure from the fuel system. On 3.8L and 5.0L engines with CFI, relieve the system pressure at the pressure relief valve mounted on the throttle body. Special tool T80L-9974-A, or its equivalent, is needed for this procedure.
- On the 2.3L turbocharged engines with EFI this valve is located in the flexible fuel supply tube approximately 12 inches (305mm) back from where it connects to the engine fuel rail on the left side of the engine compartment.
- On the 3.8L and 5.0L with EFI, the valve is located in the metal engine fuel line at the right front corner of the engine.
Before opening the fuel system on EFI engines:
- Remove the fuel tank cap.
- Disconnect the vacuum hose from the fuel pressure regulator located on the engine fuel rail.
- Using a hand vacuum pump, apply about 25 in.Hg to the pressure regulator. Fuel pressure will be released into the fuel tank through the fuel return hose.
- Raise and support the rear end on jackstands.
- Disconnect the battery ground cable.
- Siphon off as much gasoline as possible into an approved container.
On cars with fuel injection, the fuel tank has small reservoirs inside to maintain the fuel level at or near the fuel pick-up. These reservoirs are difficult to drain in as much as they may block the siphoning hose. You'll have to try different angle and repeated attempts with the siphoning hose. Be patient.
- Place a pan under the fuel fill hose and disconnect the fuel filler hose at the tank. Pour any drained fuel into an approved container.
On 1989-92 models the exhaust pipe and exhaust shields must be removed from car first, refer to Engine section for proper removal and installation procedures
- Place a floor jack, cushioned with a length of wood, under the fuel tank.
- Remove the fuel tank strap nuts and lower the fuel tank just enough to disconnect the fuel liquid and vapor lines, and the fuel sending unit wire.
- Remove the air deflector from the tank retaining straps. The deflector is retained with pop rivets.
- On cars cars equipped with a metal retainer which fastens the filler pipe to the tank, remove the screw attaching the retainer to the fuel tank flange.
- Continue lowering the tank once all lines are disconnected, and remove it from the car.
- Installation is the reverse of removal. The fuel vapor line should be retaped in position in the ribbed channel atop the tank.
- Disconnect the negative battery cable and relieve the fuel system pressure.
- Siphon or pump as much fuel as possible out through the fuel filler pipe.
All vehicles have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during cornering and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. Repeated attempts using different hose orientations can overcome this obstacle.
- Raise and safely support the vehicle.
- Remove the exhaust pipe and exhaust shield, if equipped. Disconnect the fuel fill and vent hoses connecting the filler pipe to the tank. Disconnect one end of the vapor crossover hose at the rear over the driveshaft.
- If equipped with a metal retainer that fastens the filler pipe to the fuel tank, remove the screw attaching the retainer to the fuel tank flange.
- Disconnect the fuel lines and the electrical connector to the fuel tank sending unit. On some vehicles, these are inaccessible on top of the tank. In these cases they must be disconnected with the tank partially removed.
- Place a safety support under the fuel tank and remove the bolts from the fuel tank straps. Allow the straps to swing out of the way. Be careful not to deform the fuel tank.
- Partially remove the tank and disconnect the fuel lines and electrical connector from the sending unit, if required.
- Remove the tank from the vehicle.
- Raise the fuel tank into position in the vehicle. Connect the fuel lines and sending unit electrical connector if it is necessary to connect them before the tank is in the final installed position.
- Lubricate the fuel filler pipe with water base tire mounting lubricant and install the tank onto the filler pipe, then bring the tank into final position. Be careful not to deform the tank.
- Bring the fuel tank straps around the tank and start the retaining nut or bolt. Align the tank with the straps. If equipped, make sure the fuel tank shields are installed with the straps and are positioned correctly on the tank. Align the tank with the driveshaft.
- Check the hoses and wiring mounted on the tank top to make sure they are correctly routed and will not be pinched between the tank and body. Make sure the fuel vent hose is positioned above the vent retainer and not contacting the driveshaft.
- Tighten the fuel tank strap retaining nuts or bolts to 22-30 ft. lbs. (29-41 Nm).
- If not already connected, connect the fuel hoses and lines which were disconnected. Make sure the fuel supply, fuel return, if present, and vapor vent connections are made correctly. If not already connected, connect the sending unit electrical connector.
- Install the exhaust pipe shield, if equipped, and exhaust pipe.
- Lower the vehicle. Replace the fuel that was drained from the tank. Check all connections for leaks.