Fuel Tank Replacement

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. WHEN SERVICING FLEXIBLE FUEL VEHICLES, WEAR METHANOL RESISTANT GLOVES AND EYE PROTECTION AND AVOID BREATHING FUMES. DO NOT ALLOW METHANOL/GASOLINE MIXTURES TO CONTACT SKIN. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

Fuel Tank Assembly:

REMOVAL

1. Perform fuel system pressure release.
2. Drain fuel tank.
Fuel Tank Draining Procedure

3. Remove fuel filler tube to quarter panel screws.
4. Raise vehicle on hoist. Some models will require removal of the right rear wheel to access the fuel filler tube.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

5. Disconnect fuel pump and gauge sending unit electrical connectors.
6. Disconnect the fuel supply and return hoses from fuel pump. 7. Support tank with transmission jack. Loosen tank mounting straps and lower tank slightly. Remove hose from pressure relief/rollover valve.
8. Carefully work fuel filler tube from tank.
9. Remove tank mounting straps and lower tank.


INSTALLATION

1. Position fuel tank on transmission jack. Connect vapor separator/rollover valve hose and position insulator pad on fuel tank. Position vapor vent so that it is not pinched between tank and floor pan during installation.
2. Raise tank and fuel filler tube carefully into position. Use a light coating of power steering fluid to ease fuel filler tube installation. Ensure filler tube grommet is not damaged. Verify that the tube is installed correctly.
3. Tighten fuel tank strap nuts to 23 Nm (250 in. lbs.) torque. Remove transmission jack. Ensure straps are not twisted or bent.
4. Lubricate the metal tubes on the fuel pump with clean 30 weight engine oil. Install the quick connect fuel fittings.
5. Lower the vehicle.
6. Attach filler tube to filler neck opening in quarter panel. Tighten quarter panel screws to 2 Nm (17 in. lbs.) torque.
7. Fill fuel tank, install filler cap, and connect battery cable.


CAUTION: When using the ASO Fuel System Test, the Auto Shutdown (ASD} Relay remains energized for either 7 minutes, until the test is stopped, or until the Ignition switch is turned to the Off position.

8. Use the DRB II tester ASD Fuel System Test to pressurize the fuel system. Check for leaks.