Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the filler cap.
3. Drain the fuel tank. Refer to Fuel Tank Draining .

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

•	Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.

•	Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
4. Raise and suitably support the vehicle.
5. Remove the right rear wheelhouse extension, to gain excess to rear frame support bolts under rear facia.
6. Remove the rear frame support.

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

7. Disconnect the fuel feed line at the fuel filter and the return line near the fuel filter. Refer to Servicing Quick Connect Fittings .
8. Remove clamps from the fuel tank breather hose and EVAP hoses at the fuel tank near the fuel filter, discard clamps.
9. Disconnect the fuel tank breather hose and the EVAP hoses.
10. Remove the fuel sender electrical connector retainer.
11. Disconnect the fuel sender electrical connector.
12. Remove the fuel filter retaining bolt from the bracket.
13. Remove the EVAP vent valve retaining bolt from the bracket.

Notice: Do not bend the fuel tank straps as this may damage the straps.

14. With the aid of an assistant, support the fuel tank and remove the following components:

•	The left fuel tank retaining strap attaching bolts (2)

•	The right fuel tank strap attaching bolts (1)

•	Both fuel tank retaining straps

15. Lower the tank.

•	Place the fuel tank in a suitable work area.

•	Wipe off the male line ends with a clean shop towel.

•	Inspect all of the connectors for dirt and damage. Clean or replace components/assemblies as required.

Important: Before installing the fuel tank, refer to Fuel Tank Leak Check .

1. If you are replacing the fuel tank, remove the fuel sender assembly, exhaust heat shield, ground strap and the fuel pressure sensor and reinstall these components into the new tank. Refer to Fuel Tank Pressure Sensor Replacement and Fuel Sender Assembly Replacement and Fuel Pump Replacement .
2. With the aid of an assistant, raise the fuel tank.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the fuel tank retaining straps (2), the left attaching bolts (2) and the right attaching bolts (1).

Tighten
Tighten the fuel tank retaining strap bolts to 34 N·m (25 lb ft).

4. Connect the fuel sender electrical connector.
5. Reinstall the fuel sender electrical connector retainer.
6. Connect the fuel tank breather hose and the EVAP hoses to the fuel tank.
7. Install new clamps on the fuel tank breather hose and the EVAP hoses.
8. Install the fuel feed and the return line quick-connect fittings. Refer to Servicing Quick Connect Fittings .
9. Install the fuel filter and fuel tank ground strap to the retaining bracket.

Tighten
Tighten to 22 N·m (16 lb ft).

10. Install the EVAP vent valve to the retaining bracket.

Tighten
Tighten to 22 N·m (16 lb ft).

11. Install the rear frame support and retaining bolts.

Tighten
Tighten to 10 N·m (89 lb in).

12. Install the right rear wheelhouse extension.
13. Lower the vehicle.
14. Add the fuel and install the fuel filler cap.
15. Crank the engine for a few seconds (turn off the engine if the engine starts).
16. Check for any fuel leaks.