Fuel Tank Replacement

Fuel Tank Replacement

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure Procedures.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure Procedures.
3. Remove the fuel sender assembly electrical connector.




4. Remove the fuel feed (1), fuel return (3), and evaporative emission (EVAP) lines from the fuel sender assembly (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) Quick Connect Fitting(s) Service (Plastic Collar).




5. Remove the fuel tank strap nuts (7) and the washers (8).
6. Remove the cotter pins, (5) the washers, (4) and pins (3) from the fuel tank bracket.
7. Remove the fuel tank strap assemblies (9).
8. Support and slide the fuel tank out.
9. Remove the fuel sender assembly if replacing or servicing the tank. Refer to Fuel Sender Assembly Replacement Service and Repair.
10. Purge the tank if the tank is being serviced. Refer to Fuel System Cleaning Service and Repair.

Installation Procedure

1. Install the fuel sender assembly if replacing or servicing the tank. Refer to Fuel Sender Assembly Replacement Service and Repair.




2. Slide the fuel tank into position.
3. Install the fuel tank strap assembles (9) to the fuel tank bracket.
4. Install the pins (3), the washers (4), and cotter pins (5) to the fuel tank bracket.

Notice: Refer to Fastener Notice in Cautions and Notices.

5. Install the fuel tank strap nuts (7) and the washers (8).

Tighten the nuts to 25 Nm (18 lb ft).

6. Reconnect the fuel sender assembly electrical connector.




7. Install the fuel feed (1), fuel return (3), and EVAP lines to the fuel sender assembly (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) Quick Connect Fitting(s) Service (Plastic Collar).
8. Refill the fuel tank.
9. Inspect for leaks using the following procedure:

1. Turn the ignition ON for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON.
4. Inspect for fuel leaks.