Fuel Tank Replacement

Fuel Tank Mounting:

Fuel Tank Mounting (typical):

FUEL TANK REPLACEMENT

CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end form which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

NOTE: When working on or near the fuel tank, be sure to observe important information molded on the bottom of tank.

REMOVE OR DISCONNECT
1. Negative battery cable.

2. Relieve fuel system pressure. Refer to Fuel System Pressure Relief Procedure. Fuel System Pressure Relief Procedure

3. Drain Fuel Tank. Refer to Draining Fuel Tank. Fuel Tank Draining Procedure

4. Raise vehicle.

5. Lower fuel tank shield attaching screws and lower fuel tank shields form upper fuel tank shield.

6. Wipe Evaporative Emissions (EVAP) System hose connection at fuel sender, and then disconnect EVAP hose and clamp.

7. Wipe vent hose connection at fuel filler pipe vent, and then disconnect vent hose and clamp.

8. Wipe fuel filler pipe connection at fuel tank, and then disconnect fuel filler pipe and clamp.

NOTE: If nylon fuel feed or return pipes becomes kinked, and cannot be straightened, they must be replaced. Do not attempt to repair sections of nylon fuel pipes. If damaged, replace.

9. Fuel feed and return pipe quick-connect fittings at fuel sender assembly. Refer to Servicing Quick-Connect Fittings. Servicing Quick-Connect Fittings

10. Fuel sender assembly electrical connector.

NOTE: Do not bend fuel tank retaining straps as this may damage straps.

11. With the aid of an assistant, support fuel tank and remove front fuel tank retaining strap attaching bolts and fuel tank. Place fuel tank in a suitable work area.

DISASSEMBLE
1. Fuel sender assembly from fuel tank. Refer to Fuel Sender Assembly/Service and Repair. [1][2]Fuel Sender Assembly Replacement

2. Fuel tank vent hose.

ASSEMBLE
1. Fuel tank vent hose.

2. Fuel sender assembly to fuel tank. Refer to Fuel Sender Assembly/Service and Repair.

INSTALL OR CONNECT
1. Fuel filler pipe and fuel filler pipe attaching screws (If removed). Tighten fuel filler pipe attaching screws to 6 Nm (53 lb in).

2. With the aid of an assistant, position and support fuel tank. Install fuel tank retaining strap front attaching bolts. Tighten front fuel tank retaining strap bolts to 32 Nm (24 lb ft).

3. Fuel filler pipe and clamp.

4. Fuel tank vent hose and clamp.

5. EVAP hose and clamp.

6. Fuel sender assembly electrical connector.

7. Fuel feed and return pipe quick-connect fittings to fuel sender assembly. Refer to Servicing Quick-Connect Fittings. Servicing Quick-Connect Fittings

8. Lower fuel tank shields on upper fuel tank shield with attaching screws. Tighten lower fuel tank shield attaching screws to 1.9 Nm (17 lb in).

9. Lower vehicle.

10. Add fuel and install fuel filler cap.

11. 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.