Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining .

Caution: 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.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
4. Remove the muffler. Refer to Muffler Replacement .
5. Remove the propeller shaft, if equipped. Refer to Propeller Shaft Replacement .

Notice: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

6. Disconnect the evaporative emission (EVAP) canister vent and fresh air hoses:

6.1.	Grasping both sides of the quick-connect fitting, twist the female connector 1/4 turn in each direction in order to loosen dirt within the quick-connect fitting.

6.2.	Blow any dirt out of the quick-connect fitting using compressed air.

6.3.	Squeeze the plastic retainer release tabs.

6.4.	Pull the connection apart.

6.5.	Inspect both ends of the quick-connect fitting for dirt and burrs.




7. Remove the fuel filler pipe, EVAP vent hose, and fresh air hose from the fuel tank.

Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12  in) diameter to adequately catch the fluid.

8. Disconnect the chassis fuel supply line from the tank.
9. Disconnect the electrical connectors:

9.1.	Fuel tank electrical connectors

9.2.	EVAP solenoid electrical connector

10. Remove the 36-volt battery positive cable, if equipped. Refer to 36-Volt Battery Positive Cable Replacement .




Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

Important: Do not disassemble the rear drive module (RDM). It is not necessary to touch the RDM for fuel tank removal.

11. Support the fuel tank.
12. Remove the fuel tank strap bolts and fuel tank straps.
13. Lower the fuel tank from the underbody of the vehicle.
14. Remove the fuel tank module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .

1. Install the fuel tank module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .



2. Install the fuel tank heat shield and fuel tank assembly into the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the fuel tank straps and tighten the bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

4. Install the 36-volt battery positive cable, if equipped. Refer to 36-Volt Battery Positive Cable Replacement .



5. Install the fuel filler pipe, EVAP vent, and fresh air hoses to the fuel tank.
6. Connect the electrical connectors:

6.1.	Fuel tank electrical connector

6.2.	EVAP solenoid electrical connectors

7. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose.

Tighten
Tighten the clamp to 5 N·m (44 lb in).




8. Connect the EVAP canister vent and fresh air hoses to the fuel tank hoses.
9. Install the muffler. Refer to Muffler Replacement .
10. If equipped, install the propeller shaft. Refer to Propeller Shaft Replacement .
11. Lower the vehicle .
12. Fill the fuel tank with gasoline.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
14. Prime the fuel system:

14.1.

Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.

14.2.

Repeat the previous step twice.

14.3.

Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.

14.4.

If the engine does not start, repeat steps 13.1-13.3.