Removal and Replacement

REMOVAL PROCEDURE




1. Relieve fuel system pressure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Hoist and Additional Support Caution in Service Precautions.

3. Raise the vehicle.
4. Disconnect the quick-connect fitting at the fuel filter.
5. Disconnect the quick connect fittings at the end of the fuel lines.




6. Remove the muffler support bolts.
7. Remove the exhaust rubber hangers. Allow exhaust system to rest on suspension support.
8. Remove the hoses at tank from filler, vent and vapor pipes.
9. With aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.
10. Lower the fuel tank.
11. Disconnect the fuel tank pressure sensor electrical connector.
12. Disconnect the fuel sender electrical connector.
13. Disconnect the [1][2]EVAP line from the fuel sender.
14. Remove the tank from the vehicle.
15. Remove the fuel sender assembly from the tank.

INSTALLATION PROCEDURE

IMPORTANT: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.




1. Reinstall the fuel sender assembly to tank.
2. With the aid of an assistant, raise the fuel tank (1) to body.
3. Reconnect the [1][2]EVAP line to the fuel sender.
4. Connect the fuel tank pressure sensor electrical connector.
5. Connect the fuel tank sender electrical connector.
6. Reinstall the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

7. Install the fuel tank retaining straps.

Tighten
Tighten the bolts to 35 N.m (26 lb ft).

8. Connect the hoses to filler, vent and vapor pipes.
9. Reinstall the exhaust rubber hangers.
10. Reinstall the muffler support bolts.

Tighten
Tighten the bolt to 15 N.m (11 lb ft).

11. Install the nylon fuel line and fuel filter quick-connect fittings.
12. Lower the vehicle.
13. Refill the tank and reinstall the fuel fill cap.
14. Connect the negative battery cable.
15. Inspect for fuel leaks.
15.1. Turn the ignition switch ON for 2 seconds.
15.2. Turn the ignition switch OFF for 10 seconds.
15.3. Turn the ignition switch ON.
15.4. Check for fuel leaks.