Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.




1. Ensure that fuel level in tank is less than 1/4 full. If necessary, drain fuel tank to at least this level. Refer to "Fuel Tank Draining" procedure in this service manual.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

2. Position vehicle on hoist.




Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

3. Disconnect negative battery cable.

Caution: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

4. Relieve fuel system pressure. (Refer to "Fuel System Pressure Relief" in this section of the service manual.)



5. Raise vehicle to a comfortable working position.
6. Remove exhaust system intermediate pipe (with muffler).
7. Remove rear heat shield retaining bolts.



8. Remove fuel filler pipe lower bracket attachment screw.




Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12  in) diameter to adequately catch the fluid.

9. Disconnect EVAP canister vent hose.
10. Loosen fuel filler pipe hose clamp closest to fuel tank.
11. Disconnect quick connect at recirculation line.

Important: If there are more than three gallons of fuel in the tank, insert a suitable siphon hose into tank filler neck and remove remaining fuel into a certified fuel handling cart.

12. Disengage filler pipe hose from fuel tank.



13. Remove tank grounding strap attachment nut located near the fuel filter.
14. Remove fuel tank strap bracket (fuel line stone chip guard) protecting fuel line connections between fuel tank and chassis fuel bundle.




Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

15. Disconnect fuel feed line after fuel filter.
16. Disconnect fuel return and EVAP canister purge lines between tank and chassis fuel bundle.
17. Disconnect fuel tank electrical connentions.
18. Loosen front tank strap bolts, but do not remove.
19. With aid of an assistant, remove the two rear tank retaining strap bolts.

•	Lower rear half of tank and slide the fuel tank down and out rearward.

•	Remove fuel tank from vehicle.

Important: There were two types of fuel tank assemblies used during early production of L-Series vehicles. Both types are under the same part number. The tank assemblies differ in the fact that one tank has a rubber shim on the top of the tank covering the fuel line coming from the fuel pump and going to the fuel filter. The other tank incorporates a design change and does not require the addition of the rubber shim.

LS27, LS30, or LS31 indicates that the tank DOES require a rubber shim.

LS32 indicates that the tank DOES NOT require a rubber shim.

1. The above illustration shows the location of the fuel tank mounting shim.

•	If the fuel tank code is LS27, LS30, or LS31, obtain service replacement fuel tank mounting shim (P/N 21019723) and install on fuel tank at location indicated in above illustration.

•	If fuel tank code is LS32, no fuel tank shim is required.




2. With aid of an assistant, position fuel tank under vehicle.
3. Attach electrical connectors to fuel pump and tank pressure sensor.
4. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts to underbody.

Tighten
Tighten the fuel tank mounting strap to 20 N·m (15 lb ft)

Notice: Replace plastic fuel retainer whenever the fuel supply is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

5. Install new retainers into female portion of quick-connect fittings on underbody fuel and EVAP canister purge lines.

Important: Lubricate male ends of filter with clean engine oil to ease installation.

6. Connect fuel feed return and upper lines.
7. Install fuel tank grounding attachment nut located near the fuel filter.

Tighten
Tighten the fuel tank grounding attachment nut to 4.5 N·m(40 lb in)





Important: Ensure that EVAP vent solenoid pipe is installed in position on filler pipe bracket.

8. Loosely install filler pipe lower bracket attachment screw but do not tighten.



9. Install fill neck to fuel tank.

Important: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6mm (1/4 in.) of the end of the connector hose.

10. Tighten hose clamp on filler pipe to fuel tank connecting hose.

Tighten
Tighten the fuel fill neck-to-fuel tank clamp to 5 N·m (44 lb in).




11. Connect EVAP canister vent pipe at quick connect to canister vent hose.
12. Tighten lower attachment screw on filler pipe to the underbody.

Tighten
Tighten the fuel fill pipe-to-body to 13 N·m (9.6 lb ft).

13. Install heat shield.

Tighten
Tighten the rear heat shield to 7 N·m(52 lb in).




14. Install fuel tank strap bracket (fuel line stone chip gaurd).

Tighten
Tighten the Fuel Tank Stone Guard-to-Body to 10 N·m (89 lb in).




15. Install intermediate pipe (with muffler).
16. Add fuel and connect negative battery cable.
17. Prime fuel system.

•	Using ignition, cycle switch On for five seconds and then Off for 10 seconds. Repeat this twice.

•	Examine fuel lines for leaks.

•	Crank engine until it starts (allowing a maximum of 20 seconds of cranking time).