Fuel Tank Removal and Installation

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL CAUSING PERSONAL INJURY OR A FIRE HAZARD.

1. Drain the fuel tank.
2. Remove the driveshaft. For additional information, refer to Drive Propeller Shafts, Bearings and Joints.







3. Loosen the hose clamp at the fuel tank filler pipe and disconnect the filler pipe.

CAUTION: Some fuel will remain in filler pipe after draining the fuel tank. Carefully drain the filler pipe into an approved container.







4. Disconnect the fuel tank electrical connector.







5. Position the fuel line shield aside.
1 Remove the pin-type retainers.
2 Remove the bolt.







6. Disconnect the fuel delivery line and vapor tube located forward of the fuel tank on the left side.
^ Disconnect the ground strap.







7. Position a suitable lifting device to support the fuel tank.







8. Remove the right fuel tank support strap bolt and position the fuel tank support strap aside.







9. Remove the left fuel tank support strap bolt and position the fuel tank support strap aside.







10. Partially lower the fuel tank and disconnect the vapor tube at the top rear of the fuel tank.
11. Lower the fuel tank.

INSTALLATION







1. Raise the fuel tank slightly below the fully installed position.







2. Connect the vapor tube at the top rear of the fuel tank.







3. Connect the fuel delivery line and vapor tube.
^ Connect the ground strap.







4. Install the fuel line shield.
1 Install the pin-type retainers.
2 Install the bolt.







5. Raise the tank into position and install the right support strap and bolt.







6. Install the left support strap and bolt. Remove the lifting device.







7. Connect the fuel tank electrical connector.







8. Connect the fuel tank filler pipe hose and tighten clamp.
9. Install the driveshaft. For additional information, refer to Drive Propeller Shafts, Bearings and Joints.
10. Connect the battery negative cable.

NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

11. Turn the ignition key to the ON position to pressurize the fuel system.
12. Visually inspect the fuel system for leaks.