Fuel tank – removal and installation
Warning: Gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system.
1. Relieve the fuel system pressure (Fuel pressure relief procedure).
2. Disconnect the cable from the negative battery terminal (see Engine electrical systems).
3. Raise the vehicle and place it securely on jackstands.
4. Loosen the hose clamps for the fuel filler neck hose and for the EVAP fuel vent hose (see illustration) and disconnect both hoses from their metal pipes. Note: If the fuel tank still has a lot of fuel in it, now is the time to siphon the remaining fuel from the tank through the rubber fuel filler neck hose. Using a siphoning kit (available at most auto part stores), siphon the fuel from the tank, through the filler neck hose, into an approved gasoline container. Warning: Never start the siphoning action by mouth!
5.4 To disconnect the fuel filler neck hose and the fuel EVAP vent hose from their metal pipes, loosen the clamps on these hoses
5. Disconnect the wiring and the quick-connect fuel lines from the fuel tank.
6. Support the fuel tank with a transmission jack or with a floor jack. If you’re going to use a floor jack, put a piece of wood between the jack head and the fuel tank to protect the tank.
7. Remove the fuel tank retaining strap nuts (see illustration) and remove both retaining straps. The hinged straps are secured with fasteners on the right side of the tank. To disengage the left end of each strap from its hinge, lift up the left end of the strap, then move it to the left.
5.7 To detach the fuel tank from the bottom of the vehicle, remove these two fuel tank strap nuts, then allow the fuel tank straps to swing down (they’re hinged) and disengage the left end of each strap from its hinge by lifting up the end of the strap
8. Carefully lower the tank until you have access to the top of it, then disconnect the fuel pump module wiring and the quick-connect fit¬ting (see illustration).
5.8 Lower the fuel tank just enough to access the fuel pump/fuel level sending unit module, then disconnect the electrical connector from the module
9. Disconnect any remaining components (see illustration), then lower the tank to the floor.
5.9 Disconnect the EVAP line fitting (the EVAP line fitting has already been disconnected in this photo. If you don’t know how to disconnect this type of fitting, Fuel lines and fittings – repair and replacement)
10. Installation is basically the reverse of removal. Note the following guidelines:
a) If the fuel tank is being replaced, remove the necessary components from the old fuel tank and install them on the new tank. If you need help with any of the EVAP hoses, refer to Chapter Emissions and engine control systems.
b) Tighten the fuel tank strap nuts securely.