Fuel Tank Assembly

Fuel Tank:

Fuel Tank Insulators:

Fuel Filler Hoses:

WARNING:
- To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.
- Do Not attempt to repair sections of nylon fuel pipes. If damaged, replace.
- If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.

1. Negative battery cable.
2. Perform Fuel Pressure Release procedure.
3. Raise vehicle on hoist.
4. Drain fuel tank.
5. Filler evaporative emissions (EVAP) hose from filler EVAP pipe.
6. Fuel tank filler neck from filler neck hose.
7. Quick-connect fittings at fuel tank.
8. EVAP hose from connection (at front of tank).
9. Rubber exhaust pipe hangers to allow exhaust system to drop slightly.
10. Exhaust pipe heat shield bolts and heat shield.
11. With aid of an assistant, support tank, and remove fuel tank strap attaching bolts retaining fuel tank straps.

CAUTION: Do Not bend fuel tank straps, as this may damage straps.


12. Lower tank enough to disconnect fuel sender electrical connector and remove the retaining clips.
13. EVAP hose from fuel sender assembly.
14. EVAP hose from EVAP pipe (at rear of fuel tank).
15. Fuel tank from vehicle and place in a suitable work area.

DISASSEMBLE
If fuel tank is not being replaced proceed to "INSTALL OR CONNECT."

1. Fuel sender assembly.
2. Retainer clip from EVAP pipe.
- Note position of retaining clip for installation.
3. EVAP pipe from insulator clips.
- Note position of EVAP pipe for installation.
4. Quick-connect fittings at fuel sender.
5. Chassis to sender fuel feed and return pipe assemblies and insulator clips from fuel tank.
6. Insulator pads from fuel tank.

ASSEMBLE
1. Install insulator pads on fuel tank.
2. Install insulator clips.
3. Quick-connect fittings at fuel sender.
4. Chassis to sender fuel pipe assemblies.
5. Position EVAP pipe on insulator clips as noted during disassembly.
6. Install retaining clip on EVAP pipe.
7. Install fuel sender assembly.

INSTALL OR CONNECT
1. With the aid of an assistant, position and support fuel tank. Position fuel tank straps, loosely install fuel tank strap attaching bolts and connect:

2. EVAP hose to vapor pipe (at rear of tank).
3. EVAP hose to fuel sender assembly.
4. Fuel sender electrical connector and install retaining clips.
5. Rear fuel tank strap attaching bolts.

Tighten
Front and rear fuel tank strap attaching bolts to 47 Nm (35 lb. ft.).

WARNING:
To Reduce the Risk of Fire and Personal Injury: Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male tube ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)

6. Quick-connect fittings.
7. EVAP hose to EVAP pipe (at front of fuel tank).
8. Fuel filler EVAP hose to fuel tank.
9. Fuel filler hose to fuel tank.
10. Heat shield attaching screws and heat shield.
11. Rubber exhaust pipe hangers.
12. Lower vehicle.
13. Add fuel and install fuel filler cap.
14. Negative battery cable.

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.