Fuel Tank: Service and Repair
Fuel Tank ReplacementAT-PZEV (SULEV) model
1. Drain the fuel tank; remove the fuel pump. Using a hand pump, hose, and container suitable for gasoline, draw the fuel from the fuel tank.
2. Jack up the vehicle, and support it with jackstands.
3. Remove the fuel filter hose cover (A).
4. Remove the fuel tank cover (B).
5. Remove the fuel tank guard (C).
6. Disconnect the quick-connect fitting (D) of each hose as shown.
7. Place a jack or other support under the tank.
8. Remove the strap bolts, and let the straps (E) hang free.
9. Remove the fuel tank (F).
10. Install the parts in the reverse order of removal.
Except AT-PZEV (SULEV) model
1. Relieve the fuel pressure.
2. Drain the fuel tank, remove the fuel pump. Using a hand pump, hose, and container suitable for gasoline, draw the fuel from the fuel tank
3. Jack up the vehicle, and support it with jackstands
4. Disconnect the fuel vapor hose and quick-connect fittings
Disconnect the hoses Slide back the clamps, then twist the hoses as you pull to avoid damaging them
5. Place a jack, or other support, under the tank
6. Remove the strap bolts, and let the straps (A) fall free
7. Remove the fuel tank (B) If it sticks to the undercoat on its mount, carefully pry it off the mount
8. Install the parts in the reverse order of removal