Fuel Tank

Removal

1. Drain fuel from the fuel tank as outlined prior to fuel tank removal.

2. Raise vehicle on hoist. Refer to Section 00-02.

3. Remove the exhaust system as required. Refer to Section 09-00.

NOTE:
The nylon fuel tube connections are on top of the fuel tank and are inaccessible. They must be
disconnected with the fuel tank partially removed from the vehicle.

4. Disconnect fuel tank to filler pipe hose (9047) and fuel tank vent tubes connecting the fuel
tank filler pipe to tank. Disconnect one end of the fuel tank vent tube at the rear over the driveshaft
(4602).

5. Place a safety support under the fuel tank. Remove the bolts from the fuel tank support straps
(9092). Take care not to deform the fuel tank, fuel tank support or fuel tank support straps to avoid
affecting fuel tank capacity and/or fuel pick-up.

6. Partially remove the fuel tank and disconnect the fuel lines and electrical connector from the
fuel gauge sender, if required. Refer to Push Connect Fitting Removal.

7. Remove fuel tank from the vehicle.

Installation

1. Before proceeding, check the following items:

a. Ensure fuel vapor separator valve is installed completely on the fuel tank top.

b. Make all required fuel line, fuel return line, vapor vent and electrical connections which will
be inaccessible after the fuel tank is installed.

c. Replace or install body mounted fuel tank heat shield (9A032).

2. Check the hoses and wiring mounted on the fuel tank top to ensure they are correctly routed
and will not be pinched between the fuel tank and body or driveshaft.

3. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel tank filler pipe and
the two vent hoses with water based tire mounting lubricant. Install the fuel tank onto the fuel tank to
filler pipe hose then bring the fuel tank into final position.

4. Bring fuel tank support straps around the fuel tank and start the retaining nut or bolt. Align
fuel tank with the fuel tank support straps and driveshaft.

CAUTION:
Make sure the fuel tank vent tube is positioned above the vent retainer and not contacting the
driveshaft.

5. Tighten the fuel tank support strap retaining nuts or bolts to 29-41 N-m (22-30 lb-ft).

6. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel
return (if present) and vapor vent connections are made correctly. Trace the various lines to the
engine and refer to the applicable system illustrations to ensure the proper lines are connected.

7. Install exhaust system. Refer to Section 09-00.

CAUTION:
Ensure that fuel tank heat shields are installed and are positioned correctly. Refer to the applicable
system illustration.

8. Lower vehicle.

9. Replace fuel drained from the fuel tank.

10. Check all connections for leaks.