Removal and Replacement

REMOVAL PROCEDURE




1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Raise the vehicle and suitably support. Refer to Vehicle Lifting in Service Precautions.
3. Disconnect the quick-connect fitting at the fuel filter.
4. Disconnect the quick connect fittings at the end of the fuel lines.




5. Remove the muffler support bolts.
6. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.
7. Remove the hoses at tank from filler, vent and vapor pipes.
8. With aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.
9. Lower the fuel tank.
10. Disconnect the fuel tank pressure sensor electrical connector.
11. Disconnect the fuel sender electrical connector.
12. Remove the tank from the vehicle.
13. Remove the fuel sender assembly from the tank.

INSTALLATION PROCEDURE

IMPORTANT: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.




1. Reinstall the fuel sender assembly to tank.
2. With the aid of an assistant, raise the fuel tank (1) to body.
3. Connect the fuel tank pressure sensor electrical connector.
4. Connect the fuel tank sender electrical connector.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Reinstall the fuel tank retaining straps.

Tighten
Tighten the bolts to 35 N.m (26 lb ft).

6. Connect the hoses to filler, vent and vapor pipes.
7. Reinstall the exhaust rubber hangers.
8. Reinstall the muffler support bolts.

Tighten
Tighten the bolt to 15 N.m (11 lb ft).

9. Connect the nylon fuel line and fuel filter quick-connect fittings.
^ Apply a few drops of clean engine oil to the male connector tube ends.
^ Push the connectors together to cause the retaining tabs/fingers to snap into place.
^ Once installed pull on both ends of each connection to make sure they are secure.
10. Lower the vehicle.
11. Refill the tank and reinstall the fuel fill cap.
12. Install the negative battery cable.
13. Inspect for fuel leaks.
13.1. Turn the ignition switch ON for 2 seconds.
13.2. Turn the ignition switch OFF for 10 seconds.
13.3. Turn the ignition switch ON.
13.4. Check for fuel leaks.