Fuel Tank Replacement

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Disconnect the quick-connect fitting at the fuel filter.
5. Disconnect the fuel return pipe quick connect fitting.
6. Remove the rubber exhaust hangers. Allow the exhaust system to rest on the rear axle.
7. Remove the exhaust heat shield.
8. Loosen the fuel filler hose clamp at the fuel tank.
9. Disconnect the fuel filler hose from the fuel tank.
10. Disconnect the evaporative emission (EVAP) vapor pipe from the EVAP canister.




11. Disconnect the electrical harness from the multi-way rear body connector and fuel strap.
12. With the aid of an assistant, support the fuel tank (1).
13. Disconnect the fuel tank retaining straps.
14. Lower the fuel tank.
15. Remove the fuel sender assembly from the tank.

INSTALLATION PROCEDURE




1. Install the fuel sender assembly to the fuel tank.
2. With the aid of an assistant, raise the fuel tank (1) to the vehicle.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the fuel tank retaining straps.

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

4. Connect the wiring harness into the multi-way rear body connector.
5. Connect the EVAP vapor pipe to the EVAP canister.
6. Connect the fuel filler hose to the fuel tank.

Tighten
Tighten the fuel filler hose clamp to 3 N.m (27 lb in).

7. Install the rubber exhaust hangers.
8. Install the exhaust heat shield.

Tighten
^ Tighten the exhaust shield bolt to 2 N.m (18 lb in).
^ Tighten the exhaust shield nuts to 1 N.m (9 lb in).

9. Connect the fuel return pipe and fuel filter quick-connect fittings.
10. Lower the vehicle.
11. Refill the fuel tank.
12. Install the fuel filler cap.
13. Connect the negative battery cable.
14. Inspect for fuel leaks using the following procedure:
14.1. Turn ON the ignition, with the engine OFF for 2 seconds.
14.2. Turn OFF the ignition for 10 seconds.
14.3. Turn ON the ignition, with the engine OFF.
14.4. Inspect for fuel leaks.