Extended Range Tank

FUEL TANK - EXTENDED RANGE

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If removing the fuel tank for replacement of the fuel tank or the fuel tank solenoid valve, perform the Pressure Relief Fuel Tank Venting procedure.







3. NOTE: The jackscrew on the extended range fuel tank is accessed through an access hole in the vapor retaining cover.

If removing the fuel tank for replacement of lines, turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.

4. Carry out the Pressure Relief Fuel Line Venting procedure.
5. Disconnect the battery ground cable.







6. Disconnect the electrical connectors.







7. NOTE: Loosen the fittings slowly to allow any excess tube pressure to vent through the fitting connection.

Disconnect the upper fuel tube and the flexible tube retainer.
1 Loosen the fitting and disconnect the upper fuel tube.
2 Remove the nuts and position the fuel tubes and wiring harness into the luggage compartment.

8. Remove the rear seat.







9. Remove the bolts and nuts.







10. Remove the bolts and the partition separator.







11. Remove the bolts.







12. Remove the bolts and the frame and shield assembly.







13. Remove the bolts.







14. Remove the bolts and the fuel tank straps.







15. Install the lifting equipment and remove the extended range fuel tank.

INSTALLATION

1. NOTE:
- Replace the fuel tube O-ring seal.
- Lubricate O-rings seal with clean engine oil prior to installation.
- When tightening the fuel tube, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used.

To install, follow the removal procedure in reverse order.
- Carry out the Fuel System Leak Test procedure. Testing and Inspection