Fuel Tank Assembly

WARNING: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Relieve fuel system pressure.
3. Drain fuel tank.
4. Raise vehicle.
5. Fuel filler pipe shield.
6. Exhaust system (pipe and muffler).
7. Exhaust system heat shields.
8. Rear axle assembly.

CLEAN
- Clean all fuel pipe and hose connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.
9. Fuel feed pipe, fuel return pipe, Evaporative Emission (EVAP) pipe and vent hose at fuel sender assembly.
10. Electrical connectors.

NOTICE:
- Do Not bend fuel tank retaining straps, as this may damage straps.
11. With the aid of an assistant, support fuel tank and remove fuel tank strap front attaching bolts, fuel tank straps, and fuel tank.
- Place fuel tank in stable work area.

DISASSEMBLE
1. Fuel tank insulator pads and tank strap insulator pads if damaged,
otherwise leave on.
2. Fuel sender assembly from fuel tank.

ASSEMBLE
1. Fuel sender assembly to fuel tank.
2. Tank strap insulator pads and fuel tank insulator pads, if needed.
- Peel off release paper on insulators and apply to tank and straps.

INSTALL OR CONNECT
1. Hook rear end of fuel tank straps into underbody bracket.
2. With the aid of an assistant, position and support fuel tank.
Position fuel tank straps and loosely install front fuel tank strap attaching bolts.

Tighten
- Front fuel tank strap attaching bolts to 33 Nm (24 lb ft.).
3. Electrical connector.
4. Fuel return pipe, fuel feed pipe, EVAP pipe, and vent hose and clamps at fuel sender assembly.
5. Rear axle assembly.
6. Exhaust system heat shields and attaching screws.
7. Exhaust system (pipe and muffler).
8. Fuel filler pipe shield.
9. Lower vehicle.
10. Add fuel and install filler cap.
11. Negative battery cable.

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