Installation

NOTE:
A new [1][2]fuel pump module o-ring is supplied with the new tank.





1. Carefully position the new o-ring in the [1][2]fuel pump module opening. After verifying the new o-ring is properly positioned in the new fuel tank, carefully install the fuel pump module with the float mechanism positioned towards the rear of the tank. See Figure 9.

CAUTION
Use caution when tightening [1][2]fuel pump module to ensure o-ring is not damaged.

2. Using the fuel pump sender wrench, tighten the fuel pump retainer.

3. Inspect fuel tank to make sure fuel tank-to-filler pipe seal is seated properly, and the fuel vapor valves are fully inserted in their grommets.

4. Lightly lubricate the seal and the fuel filler neck with petroleum jelly (such as Vaseline) to help ease filler pipe reinstallation.

CAUTION
Verify position of the ground strap near the fuel filter prior to installing the heat shield. The ground strap is normally pre-positioned on the replacement fuel tank by a piece of tape. If the tape is missing, be sure to align the ground strap with the gap in the coating on the heat shield. This positioning is important in order to maintain the ground connection between the heat shield and the ground strap.

5. Install fuel tank heat shield using supplied nuts.

6. Raise the fuel tank into position using suitable lift leaving room to access fuel line connections.

7. Connect fuel vapor tube to the restrictor without pinching or stressing the tube. Any restriction of the vapor tube may cause early fuel shut-off concerns when refueling the vehicle.

8. Connect filler pipe vent tube.

9. Position and connect the fuel tank filler pipe.

CAUTION
Make sure the braided ground strap is properly located under the head of the tank support strap bolt. The ground strap must be secured to the heat shield and to the left support strap.

10. Position both fuel tank support straps and install two retaining bolts. Tighten to 20-28 N-m (15-21 ft-lb).

11. Connect fuel filter outlet line to new fuel filter.

12. Install resonator and outlet pipe heat shields.

13. Install muffler and tailpipe assembly.

14. Visually inspect fuel tank installation to insure proper clearances between the fuel tank and the stabilizer bar. Also check to ensure heat shields are not bent or cocked. Improper clearances can cause noise, vibration and harshness concerns from shield to stabilizer bar contact.

15. Lower vehicle.

16. Connect red and white fuel line connections, and [1][2]fuel pump module electrical connection.

17. Install plastic grommet into floor pan.

18. Install rear seat cushion.

19. Replace drained fuel.

20. Connect battery negative cable and remove Memory Saver.

21. Start engine and check for leaks.

22. Fill fuel tank stopping at first click of automatic pump shut-off.

23. Wait 10-15 minutes then check all fuel tank connections for any signs of leakage.

24. Using a non-sparking device (such as an air drill) to prevent combustion, destroy the old fuel tank by drilling a number of holes in the bottom of it.