Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
Disconnect the negative battery cable.
NOTEClean the fuel and EVAP connections before disconnecting them to prevent fuel system contamination. Cap the lines to prevent leakage and contamination.
- Relieve the fuel system pressure.
- If removing a rear tank, remove the spare tire then remove the crossmember.
- Drain the fuel tank.
- Remove the fuel filler pipe and remove the tank shield, if equipped.
- Label and disconnect the EVAP lines and electrical connection from the fuel tank assembly.
- Disconnect the fuel line from the tank.
- Support the fuel tank using a suitable jack. Remove the strap bolts and the straps.
- Lower the tank halfway. Be sure the fill neck does not get hung up on the chassis harness. Detach the harness clip from the crossmember.
- Lower the tank enough so that the electrical connections are accessible. Detach the connections then fully lower the tank and remove it from under the vehicle.
- Installation is the reverse of removal. When installing the tank, be sure to inspect all lines, hoses and electrical connections first. Repair or replace as necessary. Tighten the strap bolts to 30 ft. lbs. (40 Nm). On rear tanks, tighten the crossmember bolts to 37 ft. lbs. (50 Nm).
To check for leaks, refill the tank then turn the ignition ON (engine OFF) for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON again (engine OFF) and inspect the tank and lines for leaks.