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.

Fuel Tank:

REMOVAL

1. Relieve fuel system pressure.
2. Disconnect negative battery cable.
3. Completely drain fuel tank by siphoning or pumping out through fuel filler hose.
4. Remove rear seat cushion.
5. Remove ground strap retaining screw and three remaining fuel pump assembly cover screws.

Ground Strap:

6. Remove fuel pump assembly cover.

Fuel Hose Clip:

Fuel Pump Assembly/Hoses:

7. Remove clips from fuel hoses.
8. Disconnect the fuel hoses from the 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.

Vapor Hoses:

12. Disconnect hoses from vapor tubes.
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 27-38 ft-lb (37-52Nm).
3. Connect hoses to vapor tubes.
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.

CAUTION: Fill the fuel tank with unleaded fuel only. Failure to do so may cause vehicle damage.