For 1990-2009 cars

### Removal Procedure

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the filler cap.
3. Drain the fuel tank. Refer to Fuel Tank Draining .

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

• | Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.

• | Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
4. Raise and suitably support the vehicle.
5. Remove rear bumper facia.
6. Remove the rear frame support.

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

7. Disconnect the fuel feed line at the fuel filter and the return line near the fuel filter. Refer to Servicing Quick Connect Fittings .
8. Disconnect the fuel tank breather hose and the fuel vent hose at the fuel tank near the fuel filter.
9. Disconnect the fuel sender electrical connector.

Notice: Do not bend the fuel tank straps as this may damage the straps.

10. With the aid of an assistant, support the fuel tank and remove the following components:

• | The front fuel tank retaining strap attaching bolts (2)

• | The rear fuel tank strap attaching bolts (2)

• | Both fuel tank retaining straps

11. Lower the tank.
12. Disconnect the EVAP fuel tank pressure sensor connector.

• | Place the fuel tank in a suitable work area.

• | Wipe off the male line ends with a clean shop towel.

• | Inspect all of the connectors for dirt and damage. Clean or replace components/assemblies as required.

### Installation Procedure

Important: Before installing the fuel tank, refer to Fuel Tank Leak Check .

1. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

Important: Assure the proper location of the fuel sender pipes.

2. With the aid of an assistant, raise the fuel tank and connect the EVAP line.and the fuel tank pressure sensor.
3. Install the fuel tank retaining straps (2), the front attaching bolts (2) and the rear attaching bolts (2).

Tighten

• | Tighten the front fuel tank retaining strap bolts (2) to 34 N·m (26 lb ft).

• | Tighten the rear fuel tank retaining strap bolts (2) to 34 N·m (26 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the exhaust heat shield screws.
5. Connect the fuel sender electrical connector.
6. Connect the fuel fill hose and the vent hose to the fuel tank.
7. Install the fuel feed and the return line quick-connect fittings. Refer to Servicing Quick Connect Fittings .
8. Lower the vehicle.
9. Add the fuel and install the fuel filler cap.
10. Crank the engine for a few seconds (turn off the engine if the engine starts).
11. Check for any fuel leaks.