Fuel Tank: Service and Repair

Fuel Tank Replacement

1. Relieve the fuel pressure: 2004-2005 models.
2. Remove the muffler.
3. Raise the vehicle, and support it with jackstands.
4. Place a jack, or other support, under the tank.




5. Remove the shield (A), remove the strap bolts, and let the straps (B) fall free.
6. Disconnect the fuel return hose, fuel vapor hose and quick-connect fittings. Disconnect the hoses. Slide back the clamps, then twist the hoses as you pull to avoid damaging them.
7. Drain the fuel tank: Using a hand pump, hose, and container suitable for gasoline, draw the fuel from the fuel tank.
8. Disconnect the fuel pump 5P connector (C).
9. Remove the fuel tank (D). If it sticks to the undercoat on its mount, carefully pry it off the mount.
10. Install the parts in the reverse order of removal.