Fuel Tank Removal/Installation Procedure

FUEL TANK REMOVAL/INSTALLATION PROCEDURE

REMOVAL
1. Position vehicle on hoist.
2. Disconnect battery ground cable.
3. Remove fuel filler cap before disconnecting any lines. The tank could be under a small pressure.
4. Drain fuel tank dry into the holding tank or a properly identified "Gasoline" safety container.
5. Remove screws that hold filler tube inner and outer quarter panel.
6. Raise vehicle and disconnect wiring and lines from tank.
7. Use a transmission jack to support the fuel tank and remove the blots from the fuel tank straps.
8. Lower tank slightly and carefully work filler tube from tank.
9. Lower the fuel tank, disconnect vapor separator rollover valve hose and remove the fuel tank from the vehicle.

INSTALLATION
1. Position fuel tank on transmission jack. Connect vapor separator rollover valve hose.

CAUTION: BE SURE VAPOR VENT HOSE IS CLIPPED TO THE TANK AND IS NOT PINCHED BETWEEN THE TANK AND THE FLOOR PAN DURING INSTALLATION.

2. Raise tank into position and carefully work filler tube into tank. Transmission fluid may be used as an aid to assembly.
3. Tighten strap bolts to 54.2 Nm (40 foot-pounds). Remove transmission jack.

CAUTION: BE SURE STRAPS ARE NOT TWISTED OR BENT BEFORE OR AFTER TIGHTENING STRAP NUTS.

4. Connect lines, drain tube cap and wiring connector, use new hose clamps and tighten to 1 Nm (10 inch-pounds).
5. Install and tighten filler tube to inner and outer quarter panel screws to 1.9 Nm (17 inch-pounds). On affected models be sure to install the gasket between the filler tube and the inner quarter panel, before installing the mounting screws.
6. Replace cap on drain tube using new hose clamp.
7. Fill fuel tank, replace cap, connect battery ground cable and check operation.
8. Check for leaks at hose connections.