Fuel Tank Replacement

REMOVAL
WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye protection, keep open flame away from fuel system components, and prohibit smoking in service areas.
1. Disconnect the battery negative cable.
2. Remove fuel filler cap to relieve tank pressure.
3. Drain fuel into an approved holding tank.
4. Remove the filler neck to body screws.
5. Raise vehicle on a hoist.
NOTE: Wrap the fuel supply and return hoses with a shop towel before disconnecting to absorb any fuel spilled when disconnected.
6. Remove fuel lines at tank unit.
7. Disconnect wires, including ground wire.
8. Support tank with a suitable jack.
9. Loosen two bolts holding fuel tank support straps enough to disconnect the vent line from the roll-over valve on top of tank.
10. Remove tank support strap bolts. The fuel tank is now supported only by the jack.
11. Lower the tank, and remove the filler tube.

INSTALLATION
1. Place tank insulator on top of tank.
NOTE:If insulator was damaged replace insulator.
2. Center the tank on a suitable jack under rear of vehicle.
3. Raise on jack until the vent hose can be installed on the roll-over valve.
4. Connect the fuel hoses and wires.
5. Raise jack and install support strap bolts and torque to 35 lb-ft (46 Nm).
6. Lubricate filler tube grommet with transmission fluid and slide into tank.
7. Lower vehicle, fill tank, install fuel filler cap, and connect negative battery cable.
8. START the engine and check for leaks.