Fuel Tank Assembly

Removal Procedure

Caution: Wear safety glasses when using compressed air because flying did particles may cause eye injury.

1. Remove the negative battery cable.
2. Drain fuel tank. Refer to Draining Fuel Tank
3. Raise vehicle and suitably support. Refer to Vehicle Lift Points.
4. Remove the muffler support bolts.
5. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.
6. Grasp the nylon fuel pipe connection fittings. Twist each quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel line connection fitting.
7. Use compressed air,in order to blow out dirt from the quick-connect fittings at the fuel filter, and fuel return pipes.
8. Remove the fuel return pipe quick-connect fitting at the fuel tank. Refer to Servicing Quick Connect Fittings. Service and Repair
9. Remove the fuel feed pipe quick-connect fitting at the in-pipe fuel filter.
10. Remove the hoses at tank from filler, vent and vapor pipes.
11. With aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.
12. Lower the fuel tank.
13. Remove the fuel tank pressure sensor electrical connector.
14. Remove the fuel sender electrical connector.
15. Remove the fuel tank from the vehicle.
16. Remove the fuel tank sound insulators.
17. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Tank Unit.

Installation Procedure

Caution: In order to reduce the risk of fire and personal Injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located In the female connector will swell and may prevent proper reconnection if not lubricated.

Important: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.

1. Install the fuel sender assembly to tank. Refer to Fuel Tank Unit.
2. Install the fuel sender assembly into the fuel tank.
3. Install the sound insulators.
4. With aid of an assistant, raise the fuel tank (1) to body.
5. Install the fuel tank pressure sensor electrical connector.
6. Install the fuel tank sender electrical connector.
7. Install the fuel tank.
8. Install the fuel tank retaining straps.

Tighten
- Tighten the bolts to 35 Nm (26 lb ft).
9. Install the fuel feed pipe quick-connect fining at the fuel filter
10. Install the fuel return pipe quick-connector fitting at the fuel tank.
11. Install the hoses to filler, vent and vapor pipes.
12. Install the exhaust rubber hangers.
13. Install the muffler support bolts.

Tighten
- Tighten the bolt to 15 Nm (11 lb ft).

14. Lower vehicle.
15. Refill tank.
16. Install the negative battery cable.
17. Inspect for fuel leaks through the following steps:
17.1. Turn the ignition to the ON position for 2 seconds
17.2. Turn the ignition to the OFF position for 10 seconds.
17.3. Turn the ignition to the ON position.
17.4. Check for fuel leaks.