Fuel Tank Replacement

Fuel Tank Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to Fuel Pressure Relief Service and Repair.




3. Remove the fuel from the tank (2), refer to Fuel Tank Draining Procedures.
4. Remove the fuel sender assembly (1) electrical connector.
5. Remove the following components:

* The fuel feed
* The vent
* The return
* The evaporative emission pipe quick-connect fittings at fuel sender assembly
Refer to Metal Collar Quick Connect Fitting Service Service and Repair and Plastic Collar Quick Connect Fitting Service Service and Repair.

6. Remove the strap nuts and the washers.
7. Remove the fuel tank.
Support and slide the tank out.
8. Remove the following components:

* The nuts
* The lockwashers retaining the sender assembly lock ring
* The sender
* The seal
Discard the seal once it is removed.

9. Purge the tank if the tank is being serviced. Refer to Fuel System Cleaning Service and Repair.

Installation Procedure




1. Install the following components:

* A new seal
* The sender assembly (1)
* The lock ring

2. Make sure the lock ring alignment holes fit over the tabs on the tank (2).

Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the washers and nuts retaining the fuel sender assembly lock ring.

Tighten the lock ring nuts to 11.5 Nm (100.90 lb in).

4. Install the fuel tank.
Slide the tank into position.
5. Install the strap nuts and the washers.

Tighten the nuts to 25 Nm (18 lb ft).

6. Install the following components:

* The fuel feed pipes
* The return pipes
* The vent pipes
* The vapor pipes quick-connect fittings to the fuel sender assembly
Refer to Metal Collar Quick Connect Fitting Service Service and Repair and Plastic Collar Quick Connect Fitting Service Service and Repair.

7. Inspect for leaks using the following procedure:

1. Turn the ignition ON for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON.
4. Inspect for fuel leaks.