Fuel Tank Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE




1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure.

CAUTION: Refer to Relieving Fuel Pressure Caution in Service Precautions.

2. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

3. Drain the fuel tank.
4. Disconnect the parking brake cable retainer clamps and the support along the fuel tank to provide clearance for the tank.




5. Remove the fuel tank filler tube clamp at the fuel tank.
6. Disconnect the fuel tank filler tube.
7. Disconnect the fuel tank filler tube at the fuel tank.
8. Disconnect the canister vapor tube at the control valve vapor tube.




9. Disconnect the fuel line near the right front of the fuel tank.
10. Disconnect the wiring harness clips and the fuel line clips as needed.




11. Remove the front exhaust pipe.




12. Support the fuel tank.
13. Remove the fuel tank retaining nuts.
14. Carefully lower the fuel tank.
15. Remove the fuel tank.
16. Transfer any parts as needed.

INSTALLATION PROCEDURE




1. Raise the fuel tank into position.
2. Install the fuel tank mounting straps and bolts.

NOTE:
- Refer to Fastener Notice in Service Precautions.
- Refer to Fuel Tank Strap Fastener Notice in Service Precautions.

Tighten the fuel tank strap retaining bolts to 20 N.m (15 lb ft).

3. Connect the fuel line.
4. Connect the wiring harness clips and the fuel line clips as needed.
5. Connect the fuel pump electrical connector.
6. Connect the fuel vapor line.
7. Connect the fuel tank filler tube and the fuel tank vent tube.
8. Install the fuel tank filler tube clamp at the fuel tank.
9. Install the front exhaust pipe.




10. Install the parking brake cable retainer clamps and the support.

Tighten the parking brake cable retainer clamps to 10 N.m (89 lb in).

11. Connect the negative battery cable.
12. Fill the fuel tank.
13. Perform a leak check of the fuel tank and the fuel line connections.