Removal and Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE

NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

IMPORTANT: Always maintain cleanliness when servicing the fuel system components.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise and support the vehicle. Refer to Vehicle Lifting.




4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).




5. Remove the fuel tank filler hose from the fuel tank.




6. Disconnect the fuel feed and the fuel return pipes at the fuel filter area.
7. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.




9. Separate the EVAP fresh air hose at the splice.




10. Remove the fuel tank shield push pins (2).
11. Remove the fuel tank shield (3).
12. Install a transmission jack to the fuel tank (1).

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




13. Remove the fuel tank strap bolts (2) from the fuel tank straps (3).
14. Remove the fuel tank (1) from the vehicle.
15. Place the fuel tank in a suitable work area.




16. Remove the EVAP canister.
17. Remove the fuel feed, the fuel return, and the EVAP pipe assemblies.




18. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.

INSTALLATION PROCEDURE




1. Install the insulator pad on the fuel tank.

NOTE: Refer to Nylon Pipes Notice in Service Precautions.




2. Install the fuel feed, the fuel return, and the EVAP pipe assemblies.
3. Install the EVAP canister.
4. Install the fuel tank to a transmission jack.




5. Raise the fuel tank (1) to the original position.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the fuel tank strap bolts (2).

Tighten
Tighten the bolts to 47 N.m (35 lb ft).

7. Remove the transmission jack.




8. Install the fuel tank shield (3).
9. Install the fuel tank shield push pins (2).




10. Connect the quick-connect fittings at the fuel filter area.
11. Connect the EVAP pipe at the front of the fuel tank.




12. Connect the EVAP fresh air hose at the splice.




13. Install the fuel tank filler hose to the fuel tank.




14. Fully seat the filler hose (4) on the fuel tank port (2).
15. Ensure the clamp (1) is properly located on the tank port between the bead (5) and the tank (3).

Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

16. Install the exhaust pipe to the hangers.
17. Lower the vehicle.
18. Install the fuel sender assembly.
19. Add fuel and install the fuel filler pipe cap.
20. Connect the negative battery cable.
21. Inspect for fuel leaks using the following procedure:
21.1. Turn ON the ignition, for 2 seconds.
21.2. Turn OFF the ignition, for 10 seconds.
21.3. Turn ON the ignition.
21.4. Inspect for fuel leaks.