Removal and Replacement
REMOVAL PROCEDURECAUTION: Provide additional support when a vehicle is on a hoist in the following ways:
^ Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
^ Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Remove the fuel fill pipe housing.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Remove the evap canister.
7. Disconnect the fuel fill pipe ground strap.
8. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
9. Disconnect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.
10. Cap the fuel pipes in order to prevent possible fuel system contamination.
11. Disconnect the fuel tank EVAP pipe at the EVAP canister.
12. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
13. With the aid of an assistant support the fuel tank.
14. Remove the fuel tank strap attaching bolts.
15. Remove the fuel tank straps.
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.
18. Remove the fuel fill pipe and hose from the fuel tank.
19. Remove the fuel sender assembly and the rear fuel and EVAP pipes from the fuel tank.
INSTALLATION PROCEDURE
NOTE: Refer to the Fastener Notice in Service Precautions.
1. Install the fuel fill pipe and hose to the fuel tank.
Tighten
Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in).
2. Install the fuel sender assembly and the rear fuel and EVAP pipes to the fuel tank.
3. With the aid of an assistant, position and support the fuel tank.
4. Install the fuel tank straps.
IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
NOTE: Refer to the Fastener Notice in Service Precautions.
5. Install the fuel tank strap attaching bolts.
Tighten
Tighten the fuel tank strap attaching bolts to 40 N.m (30 lb ft).
6. Install the Evap canister.
7. Connect the fuel tank EVAP pipe at the EVAP canister.
8. Remove the caps from the fuel pipes.
9. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.
NOTE: Refer to the Fastener Notice in Service Precautions.
10. Connect the fuel fill pipe ground strap.
Tighten
Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in).
11. Lower the vehicle.
12. Install the fuel fill pipe housing.
NOTE: Refer to the Fastener Notice in Service Precautions.
13. Install the fuel fill pipe housing to fill pipe bolts.
Tighten
Tighten the fuel fill pipe housing to fill pipe bolts to 2.3 N.m (20 lb in).
14. Refill the fuel tank.
15. Install the fuel filler cap.
16. Connect the negative battery cable.
17. Inspect for leaks.
17.1. Turn the ignition switch ON for 2 seconds.
17.2. Turn the ignition switch OFF for 10 seconds.
17.3. Turn the ignition switch ON.
17.4. Check for fuel leaks.