Fuel Tank Replacement

FUEL TANK REPLACEMENT (PICKUP)

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. Refer to Fuel Tank Draining Procedure.
3. Remove the fuel tank fill pipe.
4. Disconnect the EVAP canister vent solenoid electrical connector.
5. Remove the EVAP canister vent solenoid from the fuel tank.




6. If equipped, remove the fuel tank shield bolts.
7. Remove the fuel tank shield.




8. Disconnect the fuel feed and EVAP quick connect fittings.
9. Cap the fuel and EVAP lines in order to prevent possible system contamination.
10. Place a suitable adjustable jack under the fuel tank.
11. Remove the fuel tank strap bolts.
12. Remove the fuel tank straps.
13. Lower the fuel tank until the electrical connections are accessible.




14. Disconnect the fuel 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, remove the sending unit.

INSTALLATION PROCEDURE




1. If necessary, install the sending unit.
2. With the aid of an assistant, place the fuel tank onto the adjustable jack.
3. Raise the fuel tank until the electrical connections can be made.
4. Connect the fuel sending unit and pressure sensor electrical connectors.
5. Completely raise the fuel tank.




6. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

7. Install the fuel tank strap bolts.

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

8. Remove the adjustable jack from under the fuel tank.
9. Remove the caps from the fuel and EVAP lines.
10. Connect the fuel feed and EVAP quick connect fittings.




11. If necessary, install the fuel tank shield.
12. Install the fuel tank shield bolts.

Tighten the bolts to 18 N.m (13 lb ft).




13. Install the EVAP canister vent solenoid to the fuel tank.
14. Connect the EVAP canister vent solenoid electrical connector.
15. Install the fuel tank fill pipe.
16. Refill the fuel tank.
17. Install the fuel cap.
18. Connect the negative battery cable.
19. Perform 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.