Fuel Tank Replacement

Fuel Tank Mounting:

Fuel Pump/sender Installation:

REMOVE OR DISCONNECT
1. Relieve fuel system pressure.
2. Raise vehicle and suitably support.
3. Drain fuel tank. Refer to Fuel Tank Draining.
4. Lower fuel tank shield attaching screws (4) (Refer to accompanying images for numbered references) and lower fuel tank shield from upper fuel tank shield.
5. Wipe vapor hose connection at fuel sender, and then disconnect vapor hose and clamp.
6. Wipe fuel filler tube connection at fuel tank, and then disconnect fuel filler tube and clamp.
7. Fuel feed and return pipe quick connect fittings at fuel sender assembly.
8. Fuel sender assembly electrical connector.
9. With the aid of an assistant, support fuel tank and remove front fuel tank retaining strap attaching bolts (2), rear fuel tank strap attaching nuts (2), both fuel tank retaining straps (2) and fuel tank.
10. Fuel tube attaching screws (2) and fuel filler tube, if necessary.

DISASSEMBLE / ASSEMBLE
Fuel sender assembly. Refer to Fuel Sender/Fuel Pump Service.

INSTALL OR CONNECT
1. Fuel filler tube and fuel filler tube attaching screws (2).
2. Fuel tank cross strap and fuel tank cross strap attaching screw and nut.
3. Tighten fuel tank cross strap attaching nut to 15 Nm (11 lb. ft.)
4. With the aid of an assistant, position and support fuel tank.
5. Install fuel tank retaining straps (2), front attaching bolts (2) and nuts.
6. Tighten
- Front fuel tank retaining strap bolts (2) to 32 Nm (24 lb. ft.)
- Rear fuel tank retaining strap nuts (2) to 25 Nm (18 lb. ft.)
7. Fuel filler tube and clamp.
8. Fuel tank vent hose and clamp.
9. Vapor hose and clamp.
10. Fuel sender assembly electrical connector.
11. Fuel feed and return pipe quick connect fitting to fuel sender assembly.
12. Lower fuel tank shield on upper fuel tank shield with attaching screws.
13. Lower vehicle.
14. Add fuel and install fuel filler cap.
15. Negative battery cable.

INSPECT
Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position and check for fuel leaks.