Fuel Tank Removal/Installation Procedure

Fuel Tank Mounting:

CAUTION: The fuel system remains pressurized after engine has been shut off. Release system pressure prior to opening system.

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.

NOTE: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank replacement.

REMOVAL
1. Release fuel system pressure.
2. Remove fuel filler cap and disconnect battery negative terminal.
3. Drain fuel tank.

Fuel Filler Tube Location:

4. Remove filler and vent tubes from fuel tank.

Fuel Tank Location (Gas):

5. Disconnect fuel pump electrical connector. Disconnect EVAP purge hose from pressure relief/rollover valve. Disconnect fuel hose from filter/regulator.


6. Slide a suitable jack under tank, and apply slight pressure. Remove nuts from tank straps at the crossmembers.
7. Lower tank for removal.

INSTALLATION
1. Place fuel tank on suitable jack and raise tank into position.
2. Connect mounting straps and strap nuts.
3. Torque mounting strap nuts to 41 Nm (30 ft-lbs).
4. Connect fuel pump electrical connector. Connect EVAP purge hose from pressure relief/rollover valve. Connect fuel hose from filter/regulator.
5. Install fuel filler and vent hoses.
6. Refill tank, replace gas cap, and connect battery.
7. Using the DRB II select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks.

CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test.