Removal and Replacement

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Cautions and Notices.

3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the fuel feed inlet hose (2) from the fuel filter (1).




5. Disconnect the fuel vapor hose (2) from the fuel tank.
6. Disconnect the fuel return hose (1) from the fuel tank.
7. Disconnect the fuel filler hose from the fuel tank.




8. Remove the 4 bolts (3) and the fuel tank shield (4) from the vehicle.




9. Support the fuel lank with a hydraulic jack.
10. Remove the 4 bolts (2) and the 2 fuel tank straps (1) from the vehicle.
11. Lower the fuel tank approximately 31 cm (12 in.) from the vehicle chassis.




12. Disconnect the fuel tank sender assembly electrical connector (2).
13. Disconnect the electrical connector (3) from the fuel tank pressure sensor.
14. Disconnect the fuel tank breather hose from the fuel tank.
15. Continue to lower the fuel tank until the tank can be removed from the vehicle.

INSTALLATION PROCEDURE




1. Raise the fuel tank with a hydraulic jack to within approximately 31 cm (12 in.) of the vehicle underbody.
2. Connect the electrical connector (2) to the fuel tank sender assembly.
3. Connect the electrical connector to the fuel tank pressure sensor.
4. Connect the fuel tank breather hose to the fuel tank.
5. Raise the fuel tank all the way to the vehicle chassis.

NOTE: Refer to Fastener Notice in Cautions and Notices.

6. Secure the fuel tank to the vehicle chassis with the 2 straps (1) and the 4 bolts (2).

Tighten
Tighten the strap bolts to 35 N.m (26 lb ft).




7. Install the fuel tank shield to the vehicle chassis.
8. Secure the fuel tank shield to the vehicle chassis with the 4 bolts (3).

Tighten
Tighten the bolts to 35 N.m (26 lb ft).




9. Connect the fuel vapor hose (2) to the fuel vapor pipe.
10. Connect the fuel return hose (1) to the fuel return pipe.
11. Install the fuel filter hose to the fuel tank.




12. Connect the fuel feed inlet hose (2) to the fuel filter (1).
13. Lower the vehicle.
14. Refill the fuel tank.
15. Inspect for fuel leaks.
16. Connect the negative battery cable.
17. Start the engine.
18. Inspect for fuel leaks and repair as necessary.