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.
REMOVAL
1. Perform fuel pressure release procedure.
2. Drain fuel from the fuel tank.
3. Raise vehicle on hoist.
4. Remove the exhaust system as required.
5. Disconnect fuel tank to filler pipe hose and vent hoses connecting the fuel tank filler pipe to fuel tank. Disconnect one end of the vapor crossover hose at the rear over the driveshaft.
NOTE: The connections for the rear fuel supply return and vapor tube to the fuel pump module are on top of the fuel tank and are inaccessible. They must be disconnected with the fuel tank partially lowered from the vehicle.
6. Place a safety support under the fuel tank. Remove the bolts from the fuel tank mounting straps. Take care not to deform the fuel tank or fuel tank support straps. Fuel tank capacity and/or fuel pick-up may be adversely affected.
7. Partially remove the fuel tank and disconnect the rear fuel supply return and vapor tubes at push connect fittings using Fuel Line Disconnect Tool Set T90T-9550-S. Disconnect electrical connector from the fuel pump module.
8. Remove fuel tank from the vehicle.
INSTALLATION
1. Before proceeding, check fuel pump module area for leaks. If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A.
NOTE: If fuel pump module has been removed, the fuel pump mounting gasket must be replaced.
2. Make sure evaporative emission valve is properly installed on the fuel tank top.
3. Connect all required fuel tube, fuel return tube, vapor vent and electrical connections which will be inaccessible after the fuel tank is installed.
4. Replace or install all body-mounted fuel tank shields.
5. Check the hoses and wiring mounted on the fuel tank top to make sure they are correctly routed and will not be pinched between the fuel tank and rear floor pan or driveshaft.
6. Place fuel tank in its proper position underbody.
NOTE: If required, tape hoses and wiring to fuel tank top to verify they are correctly routed and will not be pinched between fuel tank and body.
7. Lubricate the fuel tank to filler pipe hose with water-base tire mounting lubricant. Install the fuel tank onto the fuel tank to filler pipe hose; then bring the fuel tank into final position. Tighten fuel tank to filler pipe hose clamps to 2.7-3.7 Nm (24-32 lb in).
8. Bring fuel tank support straps around the fuel tank and start the retaining bolts. Align fuel tank with the fuel tank support straps and rear floor pan.
CAUTION: Make sure the fuel vent hose is positioned above the vent retainer and not contacting the driveshaft.
9. Tighten the fuel tank support straps retaining bolts to 30-40 Nm (22-29 lb ft).
10. Reconnect the fuel hoses and tubes which were disconnected. Make sure that the fuel supply, fuel return (if present) and vapor vent connections are made correctly. Trace the various tubes to the engine and refer to the applicable system illustrations to make sure the proper tubes are connected.
11. Install exhaust system.
CAUTION: Make sure that fuel tank shield is installed or possible damage to the fuel tank may occur.
12. Lower vehicle.
13. Install fuel filler neck to body bolt. Tighten to 2.7-3.7 Nm (24-32 lb in).
14. Replace fuel drained from fuel tank.
15. Check all connections for leaks.