1. Disconnect the negative battery cable and relieve the fuel system pressure.
2. Siphon or pump as much fuel as possible out through the fuel filler pipe.
Fuel injected vehicles have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during cornering and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. Repeated attempts using different hose orientations can overcome this obstacle.
3. Raise and safely support the vehicle.
4. If equipped with a metal retainer that fastens the filler pipe to the fuel tank, remove the screw attaching the retainer to the fuel tank flange.
5. Detach the fuel lines and the electrical connector to the fuel tank sending unit. On some vehicles, these are inaccessible on top of the tank. In these cases they must be disconnected with the tank partially removed.
6. Place a safety support under the fuel tank and remove the bolts or nuts from the fuel tank straps. Allow the straps to swing out of the way.
7. Partially remove the tank and detach the fuel lines and electrical connector from the sending unit, if not detached previously.
8. Remove the tank from the vehicle.
9. Raise the fuel tank into position in the vehicle. Connect the fuel lines and sending unit electrical connector if it is necessary to connect them before the tank is in the final installed position.
10. Lubricate the fuel filler pipe with water base tire mounting lubricant and install the tank onto the filler pipe, then bring the tank into final position. Be careful not to deform the tank.
11. Bring the fuel tank straps around the tank and start the retaining nut or bolt. Align the tank with the straps. If equipped, make sure the fuel tank shields are installed with the straps and are positioned correctly on the tank.
12. Check the hoses and wiring mounted on the tank top to make sure they are correctly routed and will not be pinched between the tank and body.
13. Tighten the fuel tank strap retaining nuts or bolts to 20-30 ft. Lbs. (28-40 Nm).
14. If not already connected, connect the fuel hoses and lines which were detached. Make sure the fuel supply, fuel return, if present, and vapor vent connections are made correctly. If not already connected, connect the sending unit electrical connector.
15. Lower the vehicle.
16. Replace the fuel that was drained from the tank.
17. Check all connections for leaks.
Monday, March 15th, 2010 AT 4:22 PM