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Don't smoke or allow open flames near the area of your work. It is also important to avoid working in an area where a natural gas, heating oil, or propane
appliance with a pilot light is present. Gasoline fumes can travel quite a distance, so proper ventilation is a must. Also, wear safety glasses and have a
dry chemical (Class B) fire extinguisher within reach. Wash any spilled gasoline off your skin with soap and water.
This job is made much easier with an empty fuel tank, so run the vehicle until the tank is empty or siphon the fuel from the tank at the feed line- not the return line.
1. Remove the fuel filler cap to release the pressure in the tank.
2. Detach the negative battery terminal cable.
3. For fuel injected engines, relieve the fuel system pressure by removing the cap from the pressure test port on the fuel rail. Place a towel or rag under the port to catch the fuel spray when the pressure is released. Use a small punch or screwdriver to push the test port valve in to release the pressure. Be sure to wipe up any spilled gas. Replace the cap on the test port. If the engine is not fuel injected, skip this step.
4. Raise the vehicle and secure it safely on jack stands.
5. Drain any remaining fuel from the tank at the fuel supply line.
6. Label all hoses and connectors so you can reinstall them correctly on the new tank.
7. Disconnect all hoses. If the vehicle is equipped with a fuel gauge sending unit and fuel pump at the tank, disconnect it also.
8. Support the tank with a jack or suitable stand. Place a piece of wood between the jack and the tank's surface to protect it.
9. Disconnect the tank's retaining straps and let them hang out of the way.
10. Remove the tank.
11. Reverse the steps carefully to install the new tank.
