Fuel Tank Replacement

REMOVAL PROCEDURE
1. Raise vehicle.
2. Loosen the filler neck hose clamp at the fuel tank.
3. Disconnect the fuel tank filler neck from the fuel tank.
4. Support the fuel tank.
5. Remove the tank straps and fuel tank shield.
6. Lower the fuel tank.
7. Disconnect the fuel and vapor hoses and the electrical connections at the sender.
8. Remove the fuel sender and seal ring, using the tool J366O8.
9. Discard the old seal ring.
10. Purge tank, if being repaired.

INSTALLATION PROCEDURE
1. Install a new seal ring.
2. Reinstall sender using tool J366O8.
3. Raise tank slightly.
4. Reconnect the fuel and vapor hoses and the electrical connections at the sender. Ensure the ground strap is also reinstalled to the body.
5. Raise the tank fully.
6. Reinstall the fuel tank filler neck to the tank.
7. Tighten the clamp.

NOTE: The strap nuts must be tightened by steps, alternating between the tour nuts until the specified torque is reached. Otherwise, the bottom of the tank will flex upward and the fuel gauge will indicate fuel remaining in the tank when the tank runs dry.

8. Install the fuel tank brackets with insulator strips in place.
9. Install the fuel tank shield.
10. Tighten the strap nuts to 45 Nm (33 lb ft).
11. Replenish fuel.
12. Reinstall fuel tank filler cap.
13. Reconnect the negative battery cable. If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
14. Check for leaks.