See Figures 1, 2 and 3
REMOVAL & INSTALLATION
- Disconnect the negative battery cable and relieve the fuel system pressure.
- Siphon or pump as much fuel as possible out through the fuel filler pipe.
Fuel injected vehicles have reservoirs inside the fuel tank to maintain fuel near the fuel pick-up during cornering or low-fuel operation. These reservoirs could block siphon hoses or tubes from reaching the bottom of the fuel tank. Repeated attempts, using different hose orientations, can overcome this obstacle.
- Raise and safely support the vehicle.
- Disconnect the fuel fill and vent hoses connecting the filler pipe to the tank. Disconnect one end of the vapor crossover hose at the rear, over the driveshaft.
- On vehicles equipped with a metal retainer fastening the filler pipe to the fuel tank, remove the screw holding the retainer to the fuel tank flange.
- Disconnect the fuel lines and the electrical connections to the fuel tank sending unit. On some vehicles, these are inaccessible on top of the tank. In this case, they must be disconnected with the tank partially lowered.
- Place a safety support under the fuel tank and remove the bolts from the fuel tank straps. Allow the straps to swing out of the way. Be careful not to deform the fuel tank.
- Partially remove the tank and disconnect the fuel lines and electrical connection from the sending unit if required.
- Remove the tank from the vehicle.
- Raise the fuel tank into position in the vehicle. Attach the fuel lines and sending unit electrical connector, if necessary before the tank is in its final position.
- Lubricate the fuel filler pipe with water-based tire mounting lubricant. Install the tank onto the filler pipe, then bring the tank into final position. Be careful not to deform the tank.
- Bring the tank straps around the tank and start the retaining nut or bolt. Align the tank with the straps. If equipped, mane sure the fuel tank shields are installed with the straps and are positioned correctly.
- Check the hoses and wiring on top of the tank. Make sure they are correctly routed and will not be pinched between the tank and body.
- Tighten the fuel tank strap retaining nuts or bolts to 20-30 ft. lbs. (28-40 Nm).
- If not already attached, connect the fuel hoses and lines. Make sure the fuel supply, fuel return (if present) and the vapor vent attachments are made properly. If not already attached, connect the sending unit.
- Lower the vehicle. Replace the fuel that was drained from the tank. Check all connections for leaks.