Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL

1. Perform fuel pressure release procedure.
2. Drain fuel from the fuel tank.
3. Raise vehicle on hoist.
4. A fuel tank filler pipe retainer fastens the fuel tank filler pipe to the fuel tank, remove screw retaining the fuel tank filler pipe retainer to the fuel tank flange.
5. Place a safety support under the fuel tank. Take care not to deform fuel tank to avoid affecting capacity or fuel pickup. Remove the bolts from one of the RH fuel tank mounting strap and LH fuel tank mounting strap. The fuel tank support straps are hinged at the other end and can be swung out of the way.
6. Partially remove the fuel tank and disconnect the fuel pump to injector hose and electrical connector from the fuel level sensor, if required.
7. Remove fuel tank from the vehicle.

Fuel Tank:

INSTALLATION

1. Before proceeding, check the fuel level sensor for leaks. If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A.

NOTE: If the fuel pump and fuel level sensor have been removed, the fuel level sensor gasket must be replaced.

2. Make sure evaporative emission valve is installed completely on the fuel tank top.
3. Connect all required fuel tube, fuel return tube, vapor vent and electrical connectors which will be inaccessible after the fuel tank is installed.
4. Replace or install all body mounted fuel tank shields.
5. Place fuel tank in its proper position under body.

NOTE: If required, tape hoses and wiring to fuel tank top, to verify they are correctly routed and will not be pinched between fuel tank and body.

6. Lubricate the fuel tank filler pipe with water base tire mounting lubricant. Install the fuel tank onto the filler pipe; then bring the fuel tank into final position. Take care not to deform fuel tank to avoid affecting capacity and/or fuel pickup.
7. Bring RH fuel tank mounting strap and LH fuel tank mounting strap around the fuel tank and start the retaining bolt. Align fuel tank with the fuel tank mounting straps.
8. Check the hoses and wiring mounted on the fuel tank top to make sure they are correctly routed and will not be pinched between the fuel tank and body.

CAUTION: Make sure fuel tank heat shields are installed and are positioned correctly on the fuel tank or possible damage may occur.

9. Tighten the fuel tank support strap retaining bolts to 30-40 Nm (22-30 lb ft).
10. Reconnect the fuel hoses and tubes which were disconnected. Make sure the fuel supply, fuel return (if present), and vapor vent connections are made correctly. Trace the various tubes to the engine and refer to the applicable system illustrations to make sure the proper tubes are connected.
11. Lower vehicle.
12. Replace fuel drained from the fuel tank.
13. Check all connections for leaks.