Fuel Tank Replacement

CAUTION: Place a dry chemical (Class B) fire extinguisher near work area before attempting any On-Vehicle Service.


REMOVAL
1. Perform the Fuel Pressure Release procedure.
2. Remove the filler cap.
3. Drain the fuel tank.

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

4. Raise and suitably support the vehicle.
5. Remove rear bumper facia.
6. Remove the rear frame support.

Notice: Do not attempt to straighten the kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

7. Disconnect the fuel feed line at the fuel filter and the return line near the fuel filter. Refer to Quick-Connect Fittings.
8. Disconnect the fuel tank breather hose and the fuel vent hose at the fuel tank near the fuel filter.
9. Disconnect the fuel sender electrical connector.

Notice: Do not bend the fuel tank straps as this may damage the straps.

10. With the aid of an assistant, support the fuel tank and remove the following components:
- The front fuel tank retaining strap attaching bolts (2).
- The rear fuel tank strap attaching bolts (2).
- Both fuel tank retaining straps.
11. Lower the tank.
12. Disconnect the [1][2]EVAP fuel tank pressure sensor connector.
- Place the fuel tank in a suitable work area.
- Wipe off the male line ends with a clean shop towel.
- Inspect all of the connectors for dirt and damage. Clean or replace components/assemblies as required.

INSTALLATION
Before installing, perform the Fuel Tank Leak Check.

1. Install the fuel sender assembly.

Important: Assure the proper location of the fuel sender pipes.

2. With the aid of an assistant, raise the fuel tank and connect the [1][2]EVAP line.and the fuel tank pressure sensor.
3. Install the fuel tank retaining straps (2), the front attaching bolts (2) and the rear attaching bolts (2).
Tighten
Bolts to 34 Nm (26 lb ft)

4. Install the exhaust heat shield screws.
5. Connect the fuel sender electrical connector.
6. Connect the fuel fill hose and the vent hose to the fuel tank.
7. Install the fuel feed and the return line quick-connect fittings.
8. Lower the vehicle.
9. Add the fuel and install the fuel filler cap.
10. Crank the engine for a few seconds (turn off the engine if the engine starts).
11. Check for any fuel leaks.