Removal and Replacement

REMOVAL PROCEDURE




1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

3. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the quick-connect fitting at the fuel filter.
5. Disconnect the quick connect fittings at the end of the fuel lines.
6. Remove the exhaust rubber hangers. Allow exhaust system to rest on the rear axle.
7. Remove the exhaust heat shield.
8. Loosen the fuel tank filler hose clamp at the fuel tank.
9. Remove the hoses from the fuel tank filler, [1][2]EVAP vent, and EVAP vapor pipes.




10. Disconnect the electrical harness from the pass through rear body connector and fuel strap.
11. With the aid of an assistant, support the fuel tank (1) and disconnect the two fuel tank retaining straps.
12. Lower the fuel tank.
13. Disconnect the electrical harness from the multi-way rear body connector.
14. Remove the fuel tank from the vehicle.
15. Disconnect the wiring harness from the modular fuel sender assembly and fuel tank pressure sensor.
16. Remove the fuel sender assembly from the tank.

INSTALLATION PROCEDURE

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




1. Install the fuel sender assembly into the fuel tank.
2. Connect the fuel pipe and [1][2]EVAP pipe to the modular fuel sender and fill limiter vent valve.
3. Connect the wiring harness to the modular fuel sender and fuel pressure sensor.
4. With the aid of an assistant, raise the fuel tank (1) to the vehicle.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Install the fuel tank retaining straps.

Tighten
Tighten the bolts to 35 N.m (26 lb ft).

6. Connect the hoses to the fuel tank filler, [1][2]EVAP vent, and EVAP vapor pipes.
7. Tighten the filler hose clamp at the fuel tank.
8. Install the exhaust rubber hangers.
9. Connect the nylon fuel line and fuel filter quick-connect fittings.
10. Lower the vehicle.
11. Refill the tank and Install the fuel fill cap.
12. Connect the negative battery cable.
13. Inspect for fuel leaks using the following procedure:
13.1. Turn ON the ignition, for 2 seconds.
13.2. Turn OFF the ignition, for 10 seconds.
13.3. Turn ON the ignition.
13.4. Inspect for fuel leaks.