Removal and Replacement

REMOVAL PROCEDURE

CAUTION: Refer to Gasoline/Gasoline Vapors Caution In Service Precautions.

1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the right hand rear fascia bolts.
4. Remove the rear frame support.

NOTE: Refer to Nylon Fuel Lines Notice in Service Precautions.

5. Disconnect the fuel feed line at the fuel filter and the return line near the fuel filter.
6. Remove the clamps from the fuel tank breather hose and Evaporative Emission ([1][2]EVAP) hoses at the fuel tank near the fuel filter, discard the clamps.
7. Disconnect the fuel tank breather hose and the [1][2]EVAP hoses.
8. Remove the fuel sender electrical connector retainer.
9. Disconnect the fuel sender electrical connector.
10. Remove the fuel filter retaining bolt from the bracket.
11. Remove the EVAP vent valve retaining bolt from the bracket.

NOTE: Do not bend the fuel tank straps as this may damage the straps.

12. With the aid of an assistant, support the fuel tank and remove the following components:
^ The left fuel tank retaining strap attaching bolts (2)
^ The right fuel tank strap attaching bolts (1)
^ Both fuel tank retaining straps
13. Lower the tank.
^ Place the fuel tank in a suitable work area.
^ Wipe off the male line ends with a clean shop towel.
^ Inspect all of the connectors for dirt and damage. Clean or replace components and assemblies as required.

INSTALLATION PROCEDURE

IMPORTANT: Before installing the fuel tank, refer to Fuel Tank Leak Check.

1. If you are replacing the fuel tank, remove the following components and reinstall these components on the new tank:
^ The fuel sender assembly - Refer to Fuel Sender Assembly Replacement.
^ The fuel pressure sensor - Refer to Fuel Tank Pressure Sensor Replacement.
^ The exhaust heat shield nuts and remove the heat shield.
^ Install the heat shield and nuts.

Tighten
Tighten the nuts to 4 N.m (35 lb in).

2. With the aid of an assistant, raise the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the fuel tank retaining straps (2), the left attaching bolts (2) and the right attaching bolts (1).

Tighten
Tighten the fuel tank retaining strap bolts to 30 N.m (22 lb ft).

4. Connect the fuel sender electrical connector.
5. Reinstall the fuel sender electrical connector retainer.
6. Connect the fuel tank breather hose and the [1][2]EVAP hoses to the fuel tank using new clamps.
7. Install the fuel feed and the return line quick-connect fittings.
8. Install the in-line fuel filter attaching bolt and fuel tank ground strap to the retaining bracket.

Tighten
Tighten to 18 N.m (13 lb ft).

9. Install the EVAP vent valve to the retaining bracket.

Tighten
Tighten to 22 N.m (16 lb ft).

10. Install the rear frame support and retaining bolts.

Tighten
Tighten the bolts to 8 N.m (71 lb in).

11. Install the right hand rear fascia bolts.
12. Lower the vehicle.
13. Connect the negative battery terminal.
14. Add the fuel and install the fuel filler cap.
15. Crank the engine for a few seconds, turn OFF the engine if the engine starts.
16. Check for any fuel leaks.