Fuel Tank Assembly

Fuel Tank Assembly:

REMOVAL:

WARNING: To help avoid personal injury when the vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

1. Relieve fuel system pressure. Refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2. Drain the fuel tank. Refer to MAINTENANCE PROCEDURES/FUEL TANK DRAINING.
3. Disconnect the negative battery terminal.
4. Remove rear seat cushion from vehicle (if equipped).

Fuel Pump And Sending Unit Connectors:

5. Disconnect the fuel gauge sending unit and fuel pump electrical connectors and detach wire tape. Remove wire harness grommet and harness through the vehicle floor pan.
6. Remove the fuel filler hose clamp and hose from the filler neck assembly.

Filler Neck:

7. Remove fuel breather hose clamp and hose from the filler neck assembly.

Fuel Filter Location:

8. Remove fuel filter inlet hose clamp and hose from the fuel tank connecting pipes.
9. Remove fuel vapor hose clamp and hose.
10. Remove five fuel tank mounting bolts and fuel tank from the vehicle.
11. After removing the fuel tank, check hoses and pipes connected to the fuel tank for leaks, loose connections, deterioration, or other damage. Also check fuel pump and fuel level gauge sending unit gaskets for signs of any leakage. Visually inspect fuel tank for any damaged or malfunctioning parts.

INSTALLATION:

1. Install fuel pump and fuel level gauge sending unit into tank.

NOTE: Always use new gaskets if any above components are removed from the fuel tank.

2. Install the two-way check valve to the fuel tank directing the two-way check valve BLACK nozzle toward the fuel separator. See illustration of fuel tank assembly.
3. Connect all fuel hoses to fuel tank, fuel pump, and two-way check valve. See illustration of fuel tank assembly. Be sure to clamp all hoses and lines securely.
4. Install fuel tank and five mounting bolts into vehicle.
5. Connect the fuel breather hose and hose clamp to the fuel filler neck assembly.
6. Connect the fuel vapor hose and the fuel return hose and hose clamps to respective fuel lines.
7. Connect the inlet hose and hose clamp to the fuel filter.
8. Install wire harness and grommet through the vehicle floor pan.
9. Reconnect fuel pump and fuel level gauge sending unit connector.
10. Install rear seat cushion in vehicle (if equipped).
11. Reconnect negative battery terminal.
12. START vehicle and check for fuel leaks.