Removal and Replacement
REMOVALCAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAME IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE.
1. Ensure that fuel level in tank is less than 1/4 full. If necessary, drain fuel tank to at least this level. Refer to "Fuel Tank Draining" procedure.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
2. Position vehicle on hoist.
CAUTION: ANY TIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.
3. Disconnect negative battery cable.
NOTE: Fuel Supply lines Will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.
4. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief".
5. Raise vehicle to a comfortable working position.
6. Remove exhaust system intermediate pipe (with muffler).
7. Remove rear heat shield retaining bolts.
8. Remove fuel filler pipe lower bracket attachment screw.
CAUTION: WHENEVER FUEL LINES ARE REMOVED, PLACE FUEL IN AN APPROVED CONTAINER. CONTAINER OPENING MUST BE A MINIMUM OF 300 MM (12 IN.) DIAMETER TO ADEQUATELY CATCH FUEL.
9. Disconnect EVAP canister vent hose.
10. Loosen fuel filler pipe hose clamp closest to fuel tank.
11. Disconnect quick connect at recirc line.
IMPORTANT: If there are more than three gallons of fuel in the tank, insert a suitable siphon hose into tank filler neck and remove remaining fuel into a certified fuel handling cart.
12. Disengage filler pipe hose from fuel tank.
13. Remove tank grounding strap attachment nut located near the fuel filter.
14. Remove fuel tank strap bracket (fuel line stone chip guard), protecting fuel line connections between fuel tank and chassis fuel bundle.
CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR REMOVED, WRAP A SHOP CLOTH AROUND THE FITTING AND HAVE AN APPROVED CONTAINER AVAILABLE TO COLLECT ANY FUEL.
15. Disconnect fuel feed line after fuel filter.
16. Disconnect fuel return and EVAP canister purge lines between tank and chassis fuel bundle.
17. Disconnect fuel tank electrical connections.
18. Loosen front tank strap bolts, but do not remove.
19. With aid of an assistant, remove the two rear tank retaining strap bolts.
19.1 Lower rear half of tank and slide the fuel tank down and out rearward.
19.2 Remove fuel tank from vehicle.
INSTALLATION
1. With aid of an assistant, position fuel tank with heat shield and straps under vehicle.
2. Attach electrical connectors to fuel pump and tank pressure sensor.
3. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts to underbody.
Torque:
Fuel Tank Mounting Strap: 20 N.m (15 ft-lbs)
NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected. Install new retainer into female portion of connection. Care must be taken to ensure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
4. Install new retainers into female portion of quick-connect fittings on underbody fuel and EVAP canister purge lines.
NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected at fuel filter and fuel rail. Install new retainer into female portion of connection. Care must be taken to assure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
IMPORTANT: Lubricate male ends of filter with clean engine oil to ease installation.
5. Connect fuel feed return and vapor lines.
6. Install fuel tank grounding attachment nut located near the fuel filter.
Torque:
Fuel Tank Grounding Attachment Nut: 4.5 N.m (40 in-lbs)
IMPORTANT: Ensure that EVAP vent solenoid pipe is installed in position on filler pipe bracket.
7. Loosely install filler pipe lower bracket attachment screw but do not tighten.
8. Install fill neck to fuel tank.
NOTE: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6 mm (1/4 in.) of the end of the connector hose.
9. Tighten hose clamp on filler pipe to fuel tank connecting hose.
Torque:
Fuel Fill Neck-to-Fuel Tank Clamp: 5 N.m (44 in-lbs)
10. Connect EVAP canister vent pipe at quick connect to canister vent hose.
11. Tighten lower attachment screw on filler pipe to underbody.
Torque:
Fuel Fill Pipe-to-Body (Lower): 13 N.m (115 in-lbs)
12. Install heat shield.
Torque:
Rear Heat Shield: 8 N.m (69 in-lbs)
13. Install fuel tank strap bracket (fuel line stone chip guard).
Torque:
Fuel Tank Stone Guard-to-Body: 10 N.m (89 in-lbs)
14. Install intermediate pipe (with muffler).
15. Add fuel and connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)
16. Prime fuel system.
16.1 Cycle ignition On for 5 seconds and then Off for 10 seconds.
16.2 Repeat previous step twice.
16.3 Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
16.4 If engine does not start, repeat steps 16.1-16.3.