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1 Vehicle» Powertrain Management» Fuel Delivery and Air Induction» Fuel Tank» Service and Repair» Procedures» Fuel Tank Removal and Installation REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release the fuel system pressure. 2. Drain the fuel tank. 3. Detach the exhaust pipe from the rear hanger insulator. 1/10

2 4. Detach the exhaust pipe from the hanger insulator. 5. Detach the center muffler from the exhaust insulator. 2/10

3 6. Disconnect the exhaust pipe. 1. Remove the nuts. 2. Detach the exhaust pipe from the two insulators. 7. Secure the exhaust pipe in a suitable position. 3/10

4 8. Remove the heat shield. 9. Disconnect the fuel tank vent pipes and filler pipe. CAUTION: When removing the fuel tank vent and filler pipes, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may result in damage to the filler pipes. NOTE: Make a note of the position of the retaining clamp and clip to make sure that it is positioned in exactly the same position when installed. 4/10

5 10. Disconnect the fuel line quick release coupling. 11. Disconnect the evaporative emission pipe. 5/10

6 12. Place a suitable high-lift jack under the fuel tank. CAUTION: When supporting the fuel tank, use a suitable packing material to prevent damage to the underside of the fuel tank. 13. Remove the fuel tank support strap bolt. 6/10

7 14. Partially lower the fuel tank. CAUTION: When lowering the fuel tank, make sure that excessive strain is not placed on the fuel lines and electrical connectors. 15. Disconnect the rollover valve hose. 7/10

8 16. Disconnect the rollover valve hose. 17. Disconnect the fuel pump electrical connector. 8/10

9 18. Disconnect the fuel tank pressure sensor electrical connector. 19. Remove the fuel tank. INSTALLATION CAUTION: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. 9/10

10 1. To install, reverse the removal procedure. NOTE: The fuel filler and vent pipe retaining clamp and clip must be installed in the same position as removed. 2. Carry out an evaporative emission system leak test. See: Evaporative Emissions System > Component Tests and General Diagnostics > Evaporative Emission System Leak Test 10/10

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