Fuel Tank Removal and Installation

REMOVAL

WARNING:
^ DO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, POSSIBLY RESULTING IN PERSONAL INJURY.
^ FUEL SUPPLY LINES ON ALL VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE TO PREVENT POSSIBLE PERSONAL INJURY OR A FIRE HAZARD.

1. Disconnect the battery.
2. Relieve the fuel system pressure.
3. Drain the fuel tank.
4. Raise the vehicle.







5. Remove the filler pipe bolt and disconnect the filler pipe hose connections to the fuel tank.







6. Disconnect the fuel tank electrical connector.







7. Disconnect the vapor tube fitting at the left front of the fuel tank.







8. Disconnect the EVAP canister tube and hose.







9. Place a safety support under the fuel tank.







10. Remove the front bolts from the fuel tank support straps and swing the LH strap out of the way.







11. Remove the RH fuel tank support strap bolt and remove the strap.
12. Partially lower the fuel tank and disconnect the fuel line.







13. Cut outer edge of pipe-to-tank grommet to facilitate pipe removal and carefully remove the grommet from the fuel tank. Take care to avoid damage to the filler pipe check valve.

CAUTION: The filler pipe grommet must be removed prior to removing the fuel tank from the filler pipe or damage to the fill tube check valve will occur.

14. Lower the fuel tank from the vehicle.

INSTALLATION

















1. To install, reverse the removal procedure.

CAUTION: Lubricate the filler pipe check valve area and the tank-to-filler pipe grommet with Serfactant prior to assembly or damage to the filler pipe check valve will occur.

NOTE: A new grommet must be used for the installation procedure due to its destruction during removal.