Fuel Tank Removal and Installation

REMOVAL

CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the fuel tank.
3. Raise the vehicle and suitably support.




4. Remove the fuel tank shield(1).
5. With aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps (2).
6. Remove the fuel sender electrical connector.




7. Remove the fuel tank pressure sensor electrical connector.
8. Remove the hoses from the fuel sender.
9. Remove the filler, vent and vapor pipes.




10. Remove the fuel tank (2) from vehicle.
11. Remove the sound insulators (1).
12. Remove the fuel sender assembly from fuel tank.

INSTALLATION

1. IMPORTANT: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.

Install the fuel sender assembly to tank.




2. Install the sound insulators (1).
3. With the aid of an assistant, install the fuel tank (2) to the Body.

4. CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings in order to reduce the risk of fire and personal injury.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

Install the hoses to filler, vent and vapor pipes.




5. Install the fuel tank pressure sensor electrical connector.
6. Install the fuel tank sender electrical connector.




7. Install the fuel tank retaining straps (2).

NOTE: Refer to Fastener Note in Service Precautions.

Tighten
Tighten the bolts to 45 N.m (33 lb ft).

8. Install the fuel tank shield (1).
9. Lower the vehicle.
10. Refill the fuel tank.
11. Reconnect the negative battery cable.
12. Inspect for fuel leaks through the following steps:
1. Turn the ignition switch to the ON position for 2 seconds.
2. Turn the ignition switch to the OFF position for 10 seconds.
3. Turn the ignition switch to the ON position.
4. Check for fuel leaks.