Fuel Tank Removal and Installation

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. THIS MAY RESULT IN PERSONAL INJURY OR DEATH.

1. Release fuel system pressure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Remove fuel cap slowly to release tank pressure.
5. Raise and support the vehicle.
6. With vehicle on a hoist, drain fuel from tank. Drain fuel tank.

CAUTION: There may be fuel in the fill tube. Remove hose carefully to reduce fuel splash.

7. Disconnect fuel tank from rubber fill hose.

NOTE: wrap shop towels around hoses to catch any gasoline spillage.




8. Remove bolts from the fuel tank straps.




9. Disconnect fuel line, in the front of the fuel tank. This is a quick connect fitting.
10. Lower fuel tank and remove the EVAP line and recirculation line.
11. Remove vacuum line from LDP.




12. Unlock the electrical connector then disconnect the electrical connector
13. Remove hoses from EVAP canister.
14. Remove fuel tank from vehicle.


INSTALLATION




1. Position fuel tank on transmission jack.
2. Raise fuel tank into position.
3. Connect vacuum line to LDP.
4. Install EVAP line and recirculation line.




5. Connect electrical connector and lock the connector.
6. Connect the fuel line. Refer to Quick Connect Fittings.
7. Connect fuel fill tube to tank inlet. Tighten hose clamp to 4.1 N.m (38 in. lbs.) torque.




8. Position fuel tank straps. Tighten fuel tank strap bolts to 22.5 N.m (200 in. lbs.) torque. Remove transmission jack. Ensure straps are not twisted or bent.
9. Lower vehicle.
10. Fill fuel tank, install filler cap.
11. Install the negative battery cable.
12. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
13. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.