Fuel Tank Assembly

Fuel Tank Shield:

Fuel Pipes At Fuel Sender Assembly:

REMOVAL PROCEDURE

WARNING: Failure to follow these precautions could cause vehicle damage, sedous personal injury, or death.
- Provide additional support when a vehicle is on a hoist.
- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal This helps avoid a tip-off.

1. Disconnect the negative battery cable.
2. Perform the Fuel Pressure Release Procedure.
3. Drain the fuel tank.
4. Raise the vehicle.
5. Remove the lower fuel tank shield attaching screws and the lower fuel tank shields from the upper fuel tank shield.
6. Wipe the vent hose connection at the fuel filler vent pipe.
7. Disconnect the vent hose (1) and the clamp (2).
8. Wipe the fuel filler pipe connection at the fuel tank.
9. Disconnect the fuel filler pipe (4) and the clamp (3).
10. Wipe the EVAP hose connection at the fuel sender.

Notice:
- Replace nylon fuel feed or return pipes if the pipe becomes kinked and cannot be straightened.
- Do Not attempt to repair sections of nylon fuel pipes. Replace the pipes if they are damaged.

11. Disconnect the EVAP hose (1) and the clamp (2).
12. Disconnect the fuel feed (3) and the fuel return (4) quick-connect fittings from the fuel sender assembly.
13. Disconnect the fuel sender electrical connector.
14. With the aid of an assistant, support the fuel tank.

CAUTION: Do Not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

15. Remove the fuel tank strap front attaching bolts and the fuel tank.
16. Place the fuel tank in a suitable work area.
17. If the fuel filler pipe needs to be replaced, remove the fuel filler pipe attaching screws, the ground strap (Wagon only), and the fuel filler pipe.

18. Remove the fuel sender assembly from the fuel tank.
19. Remove the fuel tank vent hose.

INSTALLATION PROCEDURE
1. Install the fuel tank vent hose.
2. Install the fuel sender assembly to the fuel tank.
3. If the fuel filler pipe was replaced, install the fuel filler pipe, the ground strap (Wagon only), and the fuel filler pipe attaching screws.

Tighten
Screws to 6 Nm (53 lb. in)
Screws on Wagons are 1.9 Nm (17 lb. in).
Ground strap screw (Wagon only) to 4 Nm (35 lb. in).

4. With the aid of an assistant, position and support the fuel tank.
5. Install the front fuel tank strap attaching bolts.

Tighten
Bolts to 32 Nm (24 lb. ft).

6. Connect the fuel filler pipe (4) and the clamp (3).
7. Connect the fuel tank vent hose (1) and the clamp (2).
8. Connect the fuel sender electrical connector.
9. Connect the fuel feed (3) and the fuel return (4) quick-connect fittings to the fuel sender assembly.
10. Connect the EVAP hose (1) and the clamp (2).
11. Install the lower fuel tank shields on the upper fuel tank shield with the attaching screws.

Tighten
Screws to 1 Nm (9 lb. in).

12. Lower the vehicle.
13. Refill the fuel tank.
14. Install the fuel filler cap.
15. Connect the negative battery cable.
16. Inspect for leaks.
16.1. Turn the ignition switch ON for two seconds.
16.2. Turn the ignition switch OFF for ten seconds.
16.3. Turn the ignition switch ON.
16.4. Check for fuel leaks.