Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.

1. Drain the fuel tank. Refer to Fuel Tank Draining.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
3. Remove the muffler assembly. Refer to Exhaust Muffler Replacement.
4. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement.




Note: Do not remove any components from the rear frame assembly once the rear frame assembly is removed from the vehicle.

5. Remove the rear frame assembly (2). Refer to Rear Frame Replacement.



6. Disconnect the filler hose (1) from the fuel tank.
7. Disconnect the filler vent tube (2) from the evaporative emission (EVAP) hose. Refer to Evaporative Emission System Hoses/Pipes Replacement.



8. Disconnect the fuel feed pipe (1) and fuel EVAP hose (2) from the chassis bundle. Refer to Fuel Hose/Pipes Replacement - Chassis.



9. Release the electrical connector interlock and disconnect the fuel tank electrical connector.
10. Remove the fuel tank electrical connector retainer from the chassis.
11. Remove the fuel tank electrical harness from the chassis mounted retainer.



12. Disconnect the EVAP hoses from the EVAP canister.
13. Pull outward on the retainer tab in order to disengage the retainer from the chassis.



14. Disconnect the electrical connector from the fuel tank pressure sensor (1).
15. Disconnect the electrical connector from the EVAP canister vent valve.



16. Support the fuel tank with a suitable jack.
17. Remove the fuel tank strap bolts.
18. Remove the fuel tank straps.

Note: Ensure the following are free from the surrounding components while lowering the fuel tank:

•	The fuel tank wiring harness

•	The EVAP wiring harness

•	The EVAP hoses at the EVAP

•	The fuel/EVAP hoses at the chassis pipes

19. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
20. Remove the following components if replacing just the fuel tank:

•	The fuel tank pump module--Refer to Fuel Tank Fuel Pump Module Replacement - Right Side.

•	The Fuel level sensor assembly--Refer to Fuel Level Sensor Replacement - Left Side.

1. Install the following components if fuel tank replacement was necessary:

•	The fuel tank pump module--Refer to Fuel Tank Fuel Pump Module Replacement - Right Side.

•	The Fuel level sensor assembly--Refer to Fuel Level Sensor Replacement - Left Side.





Note: Ensure the following are properly routed while raising the fuel tank:

•	The fuel tank wiring harness

•	The EVAP wiring harness

•	The EVAP hoses at the EVAP

•	The fuel/EVAP hoses at the chassis pipes

2. With the aid of an assistant, carefully raise the fuel tank to the vehicle.
3. Install the fuel tank straps to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the fuel tank strap bolts and tighten to 50 N·m (37 lb ft).



5. Connect the filler hose (1) to the fuel tank and tighten to 3.5 N·m (31 lb in).
6. Connect the filler vent tube (2) to the EVAP hose. Refer to Fuel Hose/Pipes Replacement - Chassis.



7. Connect the EVAP hoses to the EVAP canister.
8. Connect the EVAP purge valve and fuel tank pressure sensor electrical connectors.



9. Install the fuel tank wire harness and wire harness connector to the retainers on the chassis.
10. Connect the fuel tank electrical connector, and engage the connector interlock.



11. Connect the fuel EVAP hose (2) and the fuel feed pipe (1) to the chassis bundle. Refer to Fuel Hose/Pipes Replacement - Chassis.



12. Install the rear frame assembly (2). Refer to Rear Frame Replacement.
13. Install the propeller shaft. Refer to Rear Propeller Shaft Replacement.
14. Install muffler assembly. Refer to Exhaust Muffler Replacement.
15. Refill the fuel tank.
16. Install the fuel fill cap.
17. Inspect for fuel leaks.