Fuel Tank Replacement (Single Tank)

FUEL TANK REPLACEMENT (SINGLE TANK)

REMOVAL PROCEDURE

IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank.
3. Disconnect the vent hose quick connect fitting from the fuel tank.
4. Disconnect the fuel feed and EVAP lines from the fuel tank lines.
5. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.




6. Disconnect the EVAP lines from the EVAP canister.




7. Using an adjustable jack, support the fuel tank.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions.

8. Remove the fuel tank strap bolts.
9. Remove the fuel tank straps.
10. With the aid of an assistant, carefully lower the rear of the fuel tank.
11. Slide the front of the tank away from the frame.
12. Lower the fuel tank slightly until the electrical connectors can be accessed.




13. Disengage the sending unit connector position assurance (CPA) retainer.
14. Disconnect the sending unit and fuel pressure sensor electrical connectors.
15. Completely lower the fuel tank.
16. With the aid of an assistant, Place the fuel tank in a suitable work area.




17. If necessary, open the clip on the fuel tank and remove the fuel feed and EVAP lines.
18. If necessary, remove the fuel sending unit.

INSTALLATION PROCEDURE




1. If necessary, install the fuel sending unit.
2. If necessary, install the fuel feed and EVAP lines to the clip on the fuel tank. Close the clip.




3. Place the fuel tank onto a suitable jack.
4. With the aid of an assistant, partially raise the fuel tank.
5. Connect the fuel sender and fuel pressure sensor electrical connectors.
6. Engage the CPA retainer.




7. Completely raise the fuel tank.
8. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

9. Install the fuel tank strap bolts.

Tighten the bolts to 40 N.m (30 lb ft).

10. Remove the adjustable jack from the fuel tank.
11. Connect the vent line quick connect fitting.
12. Install the fill hose to the fuel tank.
13. Tighten the fill hose clamp at the tank.

Tighten the clamps to 2.5 N.m (22 lb in).

14. If necessary, tighten the fill pipe bracket bolts.

Tighten the bolts to 12 N.m (106 lb in).




15. Remove the caps from the fuel and EVAP pipes.
16. Connect the EVAP lines to the EVAP canister.




17. Connect the fuel and EVAP lines to the fuel tank lines.
18. Lower the vehicle.
19. Refill the fuel tank.
20. Install the fuel fill cap.
21. Connect the negative battery cable.
22. Use the following procedure in order to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.