Fuel Tank Replacement

Removing Fuel Tank:

FUEL TANK REPLACEMENT

PRELIMINARY STEPS
- Relieve fuel system pressure. Refer to Service and Repair / Fuel Pressure Relief Procedure.
- Drain fuel tank. Refer to Fuel Tank Draining under this heading.
- Raise and suitably support vehicle.

REMOVE OR DISCONNECT
1. Rear seat cushion.

Removing Floor Service Hole Cover:

2. Four screws and service floor hole cover (see image).
3. Fuel sender assembly electrical connector.
- Raise and suitably support vehicle.

Intermediate Pipe And TWC:

4. Two bolts, two nuts and resonator intermediate pipe assembly from Three Way Catalytic Converter (TWC) (see image).

Resonator Intermediate Pipe And Muffler Assemblies:

5. Two bolts and resonator intermediate pipe assembly from muffler assembly (see image).

Exhaust Heat Shield And Parking Brake Cable:

6. Three bolts and exhaust heat shield from underbody (see image).
7. Two bolts and parking brake cables from underbody (see image).
8. One bolt, one clamp and fuel filler hose from fuel tank.
9. One bolt, one clamp and fuel breather hose from fuel tank.

Fuel Hose To Pipe Connection:

10. One nut and fuel feed hose from fuel feed pipe (see image).
11. One clamp and fuel return hose from fuel return pipe at fuel tank (see image).
12. One clamp and fuel vapor hose from fuel vapor pipe at fuel tank (see image).
13. Four bolts and fuel tank from vehicle.

DISASSEMBLE
1. Eight bolts and fuel sender assembly from fuel tank.
2. Three bolts, fuel vapor hose/pipe and fuel tank vent valve from fuel tank.
3. Five bolts, fuel filler neck and gasket from fuel tank.

ASSEMBLE
- Install a new gasket on fuel filler neck.
1. Fuel filler neck to fuel tank; secure with five bolts. Tighten fuel filler neck bolts to 3.4 Nm (30 lb. in.).
2. Fuel vapor hose and fuel tank vent valve to fuel tank; secure with three bolts. Tighten fuel vapor pipe-to-fuel tank bolts to 4 Nm (35 lb. in.).
3. Fuel sender assembly to fuel tank; secure with eight bolts. Tighten fuel sender assembly bolts to 4 Nm (35 lb. in.).

INSTALL OR CONNECT
1. Fuel tank to underbody; secure with four bolts. Tighten fuel tank mounting bolts to 39 Nm (29 lb. ft.).
2. Fuel vapor hose to fuel vapor pipe; secure with one clamp.
3. Fuel return hose to fuel return pipe; secure with one clamp.
4. Fuel feed pipe to fuel feed pipe; secure with one nut. Tighten feed pipe connection nut to 30 Nm (22 lb. ft.).
5. Fuel breather hose to fuel tank; secure with one bolt and one clamp. Tighten fuel breather hose bolt to 20 Nm (15 lb. ft.).
6. Fuel filler hose to fuel tank; secure with one bolt and one clamp. Tighten fuel filler hose bolt to 20 Nm (15 lb. ft.).
7. Parking brake cables to underbody; secure with two bolts. Tighten parking brake cable bolts to 30 Nm (22 lb. ft.).
8. Exhaust heat shield to underbody; secure with three bolts. Tighten heat shield mounting bolts to 5.4 Nm (48 lb. in.).
9. Resonator intermediate pipe assembly to muffler assembly; secure with two bolts. Tighten intermediate pipe assembly-to-muffler assembly bolts to 19 Nm (14 lb. ft.).
10. Resonator intermediate pipe assembly to TWC; secure with two bolts and two nuts. Tighten intermediate pipe assembly-to-TWC nuts and bolts to 43 Nm (32 lb. ft.).
- Lower vehicle.
11. Fuel sender assembly electrical connector.
12. Floor service hole cover; secure with four screws.
13. Rear seat cushion.
- Refill tank.
14. Negative (-) battery cable. Tighten Negative (-) battery cable-to-negative (-) battery terminal retainer to 15 Nm (11 lb. ft.).

AFTER REPAIR INSPECTION
Turn ignition switch to "ON" and momentarily connect a jumper between Data Link Connector (DLC) terminals "+B" and "FP" to pressurize the fuel system. Check for any leaks.