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

Fuel Tank And Related Components:

1. Relieve fuel system pressure.
2. Disconnect negative battery cable.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy.

3. Completely drain fuel tank by siphoning or pumping out through fuel filler hose.
4. Remove rear seat cushion.

Fuel Tank Sending Unit:

5. Remove ground strap retaining screw and three remaining fuel pump assembly cover screws.
6. Remove fuel pump assembly cover.

Fuel Tubes:

7. Remove clips from fuel hoses.

Fuel Tank Sending Unit And Pump:

8. Disconnect fuel hoses from fuel pump assembly.
9. Raise and support the vehicle.

Filler Neck Clamp:

10. Loosen filler neck clamp and disconnect hose from filler neck.

Overflow Tube:

11. Loosen clamp and disconnect overflow hose from overflow tube.
12. Disconnect the fuel tank vent tube from the vapor tube.
13. Remove fuel tank straps.
14. Remove three fuel tank heat shield attaching bolts from tank.
15. Remove fuel tank.

INSTALLATION

1. Place fuel tank onto heat shield and install shield attaching bolts into fuel tank.
2. Install fuel tank straps. Tighten to 37-52 Nm (27-38 lb ft).
3. Connect the fuel tank vent tube to the vapor tube.
4. Connect filler neck hose and install attaching clamp.
5. Connect hose to overflow tube and install attaching clamp.
6. Lower vehicle.
7. Connect the hoses to fuel pump assembly.
8. Install clips onto fuel hoses.
9. Position pump assembly cover and ground strap and install retaining screws.
10. Connect pump assembly electrical connector.
11. Install rear seat cushion.
12. Connect negative battery cable.
13. Start engine and check for leaks.