Removal & Installation
- Drain fuel tank. See DRAINING FUEL TANK .
- Move front seats as far forward as possible. Fold rear seat forward. Pull carpet forward. Remove screws from fuel pump cover and remove cover. Disconnect fuel pump electrical connector. See Figure.
- Raise and support vehicle.
- Remove left-side protective cover from underside of vehicle. Remove screws holding parking brake cable bracket and pull cable downward. See Fig 1.
- Disconnect fuel filler pipe from fuel tank. Disconnect quick-release fuel line fitting at fuel filter. Disconnect quick-release fittings for EVAP system. Catch any spilling fuel. See Fig 2.
- Apply rust solvent to fuel tank strap nuts. Support fuel tank and remove nuts. Remove tank straps and lower tank slightly. Remove fuel line bracket and fuel lines by right-side heat shield. Lower and remove fuel tank.CAUTION: Reinstall cap nut into fuel tank immediately after removing fuel pump. Otherwise threads may distort and cause problems when reinstalling.
- Transfer fuel pump to new fuel tank. See FUEL PUMP . Disconnect fuel lines and fuel filter. Transfer EVAP canister unit and heat shields.
- Raise fuel tank into position under vehicle. Ensure all lines and components are properly fastened to tank before raising completely. Ensure foam pads on top of tank are properly positioned. Secure fuel lines in brackets and secure heat shield. Install tank straps and thread nuts finger-tight. Lower tank support and tighten strap nuts to specification. See TORQUE SPECIFICATIONS .CAUTION: DO NOT tighten tank filler pipe clamp beyond 53 INCH. Lbs. (6 N.m) or pipe connection may be damaged.
- Wipe away any debris from all quick-release connections before installing. Connect all lines and ensure quick-release tabs are fully engaged. Connect fuel filler pipe to tank. Install protective cover. Ensure all connections are fitted and all fasteners are tightened to specification. See TORQUE SPECIFICATIONS . Lower vehicle.
- From inside vehicle, connect fuel pump lines, EVAP system lines and pump electrical connector. Install pump cover and assemble vehicle interior. Fill fuel system and check function. Check thoroughly for leaks and run leak diagnostic using scan tool.