Two people are required to perform this procedure.
1.Disconnect the negative battery cable.
2.Properly drain the fuel tank.
3.Raise and safely support the vehicle.
4.Detach the fuel sender connector.
5.Unfasten the muffler hanger bolts.
6.Remove the exhaust rubber hangers and allow the exhaust system to rest on the rear axle.
7.Use compressed air to blow any dirt away from all hoses and fittings prior to tank removal.
8.Disconnect the hoses from the fuel tank sender. For details, please refer to quick-connect fitting removal, located in this section.
9.Detach the hoses, at the tank, from the filler, vent and vapor pipes.
10.With an assistant's help, support the tank, then unfasten the two fuel tank retaining straps. Remove the tank from the vehicle slowly to ensure all connections and hoses have been detached.
11.Remove the hoses from the sending unit, be sure to label them.
12.Remove the sound insulators.
13.Remove the sending unit from the tank.
14.Inspect the fuel line O-rings for damage, and replace if necessary.
15.Inspect all connectors for dirt and burrs.
16.Install the sending unit in the fuel tank. Refer to Fuel Pump Removal and Installation.
17.Install the sound insulators.
18.With an assistant's help, position the fuel tank to the body of the car and secure using the retaining straps. Do not tighten them completely at this time.
19.Attach the fuel feed and return connecting line quick-connect fittings to the fuel sender. Apply a few drops of clean engine oil to the male ends of the fuel lines before connection. Push all connectors together to cause the retaining tabs to snap into place. Once connected, pull both ends of each connection to make sure they are secure.
20.Connect the hoses to the filler, vent and vapor pipes.
21.Attach the sending unit wiring.
22.Secure the fuel tank and tighten the strap bolts to 26 ft. lbs. (35 Nm).
23.Install the exhaust rubber hangers, then secure the muffler hanger bolts. Tighten the bolts to 11 ft. lbs. (15 Nm).
24.Carefully lower the vehicle, then refill the fuel tank.
25.Connect the negative battery cable.
26.Check for leaks through the following:
A.Turn the ignition to the ON position for two seconds.
B.Turn it the ignition switch to the OFF position for ten seconds.
C.Turn again to the ON position and check for fuel leaks.
Wednesday, May 12th, 2010 AT 3:01 PM