Removal and Replacement

Fuel Tank Replacement

Removal Procedure
1. Drain the fuel tank. Fuel Tank Draining Procedure
2. Raise the vehicle on a suitable hoist.






IMPORTANT: Clean all the fuel pipe and hose connections as well as the surrounding areas before disconnecting the fuel pipes and hoses.

3. Remove the plastic clip(1) between the vent hose and fuel line, the vent hose clamp(2), then disconnect the vent hose from the fuel tank.
4. Disconnect the filler tube(7) at the fuel tank.






5. Remove the two frame mounted L safety brackets.
6. Support the fuel tank.
7. With the aid of an assistant, remove the fuel tank attachment bolts.
8. Lower the fuel tank enough to remove the fuel tank cover bolts and fuel tank cover.






9. Push the fuel sender electrical connector CPA back, then disconnect the fuel sender electrical connector(5).
10. Disconnect the fuel pressure sensor electrical connector(6).
11. Disconnect the EVAP line from the fuel sender assembly(4). Plastic Collar Quick Connection Fitting Service
12. Disconnect the fuel line from the fuel sender assembly(3). Metal Collar Quick Connect Fitting Service
13. Remove the fuel tank from the vehicle and place the tank in a suitable work area.
14. Remove the fuel sender assembly from the fuel tank. Service and Repair

Installation Procedure
1. Install the fuel sender assembly with new O-rings on the fuel pipes. Service and Repair






2. Position and support the fuel tank.

NOTICE: Fastener Notice

3. Install the fuel tank fasteners to secure the fuel tank to the frame.

Tighten
Tighten the two fasteners on each bracket to 85 N.m (63 lb ft).

4. Install the two frame mounted safety brackets.

Tighten
Tighten the two fasteners on each bracket to 85 N.m (63 lb ft).






5. Connect the fuel sender assembly electrical connector(5).
6. Connect the fuel pressure sensor electrical connector(6).
7. Install the fuel feed pipe(3) to the fuel sender assembly. Metal Collar Quick Connect Fitting Service
8. Install the EVAP line(4) to the fuel sender assembly. Plastic Collar Quick Connection Fitting Service
9. Install the fuel filler vent hose(2) to the fuel tank vent pipe and install the clamp..
10. Install the clip(1) between the vent hose and fuel line.
11. Install the fuel filler neck connecting tube(7) to the fuel tank and tighten the clamp.
12. Start the engine and inspect for leaks.