Removal Procedure
- Remove the negative battery cable.
- Drain fuel tank. Refer to Fuel Tank Draining
- Raise vehicle and suitably support.
- Remove the fuel sender electrical connector.
- Remove the muffler hanger bolts.
- Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.
- Remove the hoses from fuel tank sender. Grasp filter and one nylon fuel connection line fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for other nylon fuel connection line fitting.
- Using compressed air, blow out dirt from quick-connect fittings at end of fuel filter.
- Remove the quick connect fittings by pulling release tabs back on fuel line quick connector and pulling apart.
- Remove the hoses at tank from filler, vent and vapor pipes.
- With aid of an assistant, support fuel tank and disconnect the two fuel tank retaining straps.
- Remove the tank from vehicle.
- Remove the sound insulators.
- Remove the fuel sender assembly from tank. Refer to Fuel Sender Assembly Replacement
Caution: Wear safety glasses when using compressed air in order to prevent eye injury.
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.
Installation Procedure
- Install the fuel sender assembly to tank. Refer to Fuel Sender Assembly Replacement
- Install the sound insulators.
- With aid of an assistant, install the fuel tank to body.
- Install the fuel tank retaining straps.
- Install the hoses to filler, vent and vapor pipes.
- Install the nylon fuel feed and return connecting line quick-connect fittings to fuel sender.
- Install the exhaust rubber hangers.
- Install the muffler hanger bolts.
- Install the fuel tank sender electrical connector.
- Lower vehicle.
- Refill tank.
- Install the negative battery cable.
- Check for leaks.
Tighten
Tighten the bolts to 35N·m (26 lb. ft.)
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.
Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
| - | Apply a few drops of clean engine oil to the male connector tube ends. |
| - | Push 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. |
Tighten
Tighten the bolt to 15 N·m (11 lb. ft.)
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.
| 13.1. | Turn ignition to ON position for 2 seconds. |
| 13.2. | Turn to OFF for 10 seconds. |
| 13.3. | Turn the ignition switch to the ON position. |
| 13.4. | Check for fuel leaks. |
