Fuel Tank Replacement Procedure

1. Drain remaining fuel from fuel tank following procedure in section 6C of appropriate service manual.

2. Disconnect clamps connecting fuel filler neck hose and vent line to fuel tank.

3. While supporting fuel tank, remove fuel tank retaining straps.

4. Disconnect fuel tank sending unit wires, hoses and ground strap from fuel tank. Tank will need to be lowered to gain access.

5. Remove fuel tank from vehicle.

6. Loosen sending unit tank locking cam using Kent-Moore tool J36608 or equivalent and remove fuel sending unit assembly from fuel tank. This procedure is described in detail in section 6C of appropriate service manual.

7. Install fuel tank sender unit into the replacement fuel tank.

^ Inspect and replace sending unit gasket if necessary.

^ Tighten sending unit locking cam using Kent-Moore tool J36608 or equivalent.

8. While supporting fuel tank, install fuel tank sending unit wires, hoses and the ground straps.

9. Reconnect the existing fuel tank filler neck hose and the vent pipe to the fuel tank using existing fasteners removed in step 4.

10. Using existing fuel tank anti-squeak strips, install existing fuel tank retaining straps with existing hardware. Torque bolts or nuts as follows:

^ Base Tank Nuts - 6 Nm (48 lb. in.)

^ Auxiliary Tank Bolts (If Applicable) - 33 Nm (24 lb. ft.)

11. Reconnect fuel vapor line. Refuel fuel tank with gas removed in step 1 of this procedure.

12. Reconnect negative battery cable and reset all electronic devices as noted in tank inspection procedure (step 2).

13. Install Campaign Identification Label.