Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.
- Relieve the fuel system pressure. Please refer to Relieving Fuel System Pressure for the procedure.
- Disconnect the negative battery cable.
- Drain the fuel from the tank.
- Raise and safely support the rear of the vehicle securely on jackstands.
- Remove the two plastic clips and three bolts from the fuel tank front protective shield and remove the shield.
- On 1998 California emissions and 1999-00 vehicles, remove the nuts, bolts, and clips from the EVAP canister splash shield. Remove the shield.
- Disconnect the vapor hose from the fuel vapor valve.
- Label the fuel supply and return hoses to ease installation. Loosen the clamps and disconnect the hoses from the fuel tank.
- Disconnect the fuel pump electrical connector.
- Loosen the fuel tank-to-filler pipe hose clamp and slide it toward the fuel tank. Separate the hose from the filler pipe.
- On 1998 California emissions vehicles, remove the eight fuel tank skid plate nuts and remove the skid plate.
- Place a transmission jack or other suitable support device under the fuel tank, but do not obstruct the tank holding straps.
- Remove the fuel tank holding strap retaining bolts. The tank holding straps are hinged at the front and will swing down after the retaining bolts are removed.
- Carefully lower the tank from the vehicle and place the tank in a secure spot.
If the tank is to be replaced:
- Drain the old tank and remove it from the jack or other device. Place the new tank on the jack or other device.
- Remove the fuel pump from the old tank and install it in the new tank.
- Make sure that the vapor hose is installed on the new tank.
- Raise the fuel tank into position.
- Position the fuel tank straps and tighten the retaining bolts to 21-26 ft lbs. (29-35 Nm).
- Remove the transmission jack or other device.
- On 1998 California emissions vehicles, install the fuel tank skid plate and tighten the nuts to 15-18 ft. lbs. (20-25 Nm).
- Connect the fuel supply and return hoses.
- Connect the fuel tank-to-filler pipe hose. Align and tighten the clamp.
- Connect the fuel pump electrical connector.
- Connect the fuel vapor hose.
- On 1998 California emissions and 1999-00 vehicles, install the EVAP canister splash shield.
- Position the fuel tank front protective shield and install the clips and bolts. Tighten the bolts to 39-47 inch lbs. (4.4-5.4 Nm).
- Lower the vehicle.
- Connect the negative battery cable.
- Fill the tank with gas.
- Cycle the ignition key several times from OFF to ON to build fuel pressure.
Start the engine and check for leaks and proper operation.