Fuel Tank Assembly

Fuel Tank Assembly:

REMOVAL:

WARNING: To help avoid personal injury when the vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

1. Relieve fuel system pressure. Refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2. Drain the fuel tank. Refer to MAINTENANCE PROCEDURES/FUEL TANK DRAINING.
3. Disconnect the negative battery terminal.
4. Remove the rear bumper assembly.

Fuel Pump And Fuel Level Sender Connector:

5. Disconnect the fuel gauge sending unit and fuel pump electrical connectors.
6. Remove the fuel tank filler hose cover, filler hose, and fuel tank inlet valve (breather hose).
7. Remove inlet pipe from fuel filter.
8. Remove the fuel vapor hose and fuel return hose from the fuel tank connecting pipes.
9. Remove the fuel tank protector.
10. Remove the fuel tank and cover from the vehicle.
11. After removing the fuel tank, check hoses and pipes connected to the fuel tank for leaks, loose connections, deterioration, or other damage. Also check fuel pump and fuel level gauge sending unit gaskets for signs of any leakage. Visually inspect fuel tank for any damaged or malfunctioning parts.

INSTALLATION:

1. Install fuel pump and fuel level gauge sending unit into tank.

NOTE: Always use new gaskets if any above components are removed from the fuel tank.

2. Install the fuel separator, inlet valve, and two-way check valve to the fuel tank directing the two-way check valve BLACK nozzle toward the fuel separator. See illustration of fuel tank assembly.
3. Connect fuel hoses to fuel tank, fuel pump, two-way check valve, and separator. See illustration of fuel tank assembly.
4. Install fuel tank and cover into vehicle.
5. Connect the fuel filler hose and breather hose to the fuel filler neck. Be sure to clamp all connections securely.
6. Connect the fuel vapor hose and the fuel return hose to the fuel tank connecting pipes. Be sure to clamp all connections securely.
7. Connect the inlet pipe to the in-line fuel filter.
8. Install fuel filler hose cover.
9. Reconnect fuel pump and fuel level gauge sending unit connector.
10. Install rear bumper assembly.
11. Reconnect negative battery terminal.
12. START vehicle and check for fuel leaks.