Fuel Tank Replacement (Short Wheel Base)

FUEL TANK REPLACEMENT (SHORT WHEEL BASE)

REMOVAL PROCEDURE

NOTE: Refer to Nylon Fuel Lines Notice in Service Precautions.

IMPORTANT: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace the pipes.

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




4. Disconnect the fuel supply pipe (5) quick-connect fitting.
5. Disconnect the evaporative emission (EVAP) purge pipe (6) quick-connect fitting at the EVAP canister.




6. Loosen the fuel tank filler pipe hose clamp.
7. Disconnect the fuel tank filler from the fuel tank.




8. Disconnect the vapor recirculation pipe from the filler tube.
9. Remove the fuel tank shield.




10. With the aid of an assistant, support the fuel tank.
11. Remove the fuel tank strap attaching bolts.
12. Disconnect the fuel sender and the fuel tank pressure (FTP) sensor electrical connectors at the body pass through.




13. Remove the fuel tank from the vehicle.
14. Place the fuel tank in a suitable work area.
15. If the fuel tank is not being replaced, go to the installation procedure.
16. Remove the EVAP canister.




17. Disconnect the fuel feed quick-connect fittings.
18. Remove the fuel feed pipe (5).
19. Remove the EVAP canister vent solenoid (2).
20. Remove the EVAP pipe assembly.
21. Remove the fuel sender assembly (3).

INSTALLATION PROCEDURE




1. Install the fuel sender assembly (3).
2. Install the EVAP pipe assembly.
3. Install the fuel feed pipe (5).
4. Install the EVAP canister vent solenoid (2).
5. Connect the quick-connect fittings.
6. Install the EVAP canister.




7. With the aid of an assistant, position and support the fuel tank.
8. Connect the fuel sender and the FTP sensor electrical connectors at the body pass through.




9. Install the fuel tank retaining strap attaching bolts.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the fuel tank retaining strap bolts to 47.5 N.m (35 lb ft).

10. Install the fuel tank shield.




11. Connect the vapor recirculation pipe to the fuel fill pipe.




12. Connect the fuel tank filler pipe to the fuel tank.

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




13. Connect the fuel feed pipe (5) quick-connect fitting.
14. Connect the EVAP purge pipe (6) quick-connect fitting at the EVAP canister.
15. Lower the vehicle.




16. Add fuel.
17. Install the fuel tank filler pipe cap.
18. Connect the negative battery cable.
19. Inspect for fuel leaks using the following procedure:
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.