Removal and Replacement

Fuel Tank Replacement


REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Cautions and Notices.

3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the fuel feed inlet hose (2) from the fuel filter (1).




5. Disconnect the fuel vapor hose (2) from the fuel tank.
6. Disconnect the fuel return hose (1) from the fuel tank.
7. Disconnect the fuel filler hose from the fuel tank.




8. Remove the four bolts (3) and the fuel tank shield (4) from the vehicle.




9. Support the fuel tank with a hydraulic jack.
10. Remove the four bolts (2) and the two fuel tank straps (1) from the vehicle.
11. Lower the fuel tank approximately 31 cm (12 in) from the vehicle chassis.




12. Disconnect the fuel tank sender assembly electrical connector (2), located between the partially lowered fuel tank and the vehicle chassis.
13. Disconnect the fuel tank pressure sensor electrical connector (3), located between the partially lowered fuel tank and the vehicle chassis.
14. Disconnect the fuel tank breather hose from the fuel tank, located between the partially lowered fuel tank and the vehicle chassis.
15. Continue to lower the fuel tank, until the tank can be removed from the vehicle.

INSTALLATION PROCEDURE




1. Raise the fuel tank, with a hydraulic jack, to approximately 31 cm (12 in) of the vehicle underbody.
2. Connect the fuel tank sender assembly electrical connector (2), located between the raised fuel tank and the vehicle chassis.
3. Connect the fuel tank pressure sensor electrical connector, located between the raised fuel tank and the vehicle chassis.
4. Connect the fuel tank breather hose from the fuel tank, located between the raised fuel tank and the vehicle chassis.
5. Raise the fuel tank all the way to the vehicle chassis.

NOTE: Refer to Fastener Notice in Cautions and Notices.

6. Secure the fuel tank to the vehicle chassis with the two straps (1) and four bolts (2).

Tighten
Tighten the four fuel tank strap bolts to 35 N.m (26 lb ft).




7. Install the fuel tank shield to the vehicle chassis.
8. Secure the fuel tank shield to the vehicle chassis with the four bolts (3).

Tighten
Tighten the tour fuel tank shield bolts to 35 N.m (26 lb ft).




9. Connect the fuel vapor hose (2) to the fuel vapor pipe.
10. Connect the fuel return hose (1) to the fuel return pipe.
11. Install the fuel filler hose to the fuel tank.




12. Connect the fuel feed inlet hose (2) to the fuel filter (1).
13. Lower the vehicle.
14. Refill the fuel tank.
15. Inspect for fuel leaks.
16. Connect the negative battery cable.

Tighten
Tighten the negative battery cable-to-negative battery terminal retainer bolt to 8 N.m (72 lb in).

17. Start the engine.
18. Inspect for fuel leaks and repair as necessary.