Removal and Replacement

REMOVAL PROCEDURE

NOTE: Refer to Cover and Plug Openings Notice in Service Precautions.

IMPORTANT: Always maintain cleanliness when servicing 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 the vehicle. Refer to Lifting and Jacking the Vehicle in General information.
4. Loosen the fuel tank filler hose clamp (1) at the fuel tank (3).




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




6. Disconnect the quick-connect fittings at the fuel tank.
7. Disconnect the [1][2]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. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.




10. Disconnect the [1][2]EVAP pipes from the rear of the fuel tank.
11. Disconnect the [1][2]EVAP pipe from the fuel limiter vent valve.
12. Disconnect the fuel filler neck [1][2]EVAP pipe at the rear of the fuel tank.
13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
14. If the fuel tank is not being replaced, refer to the fuel tank installation procedures.
15. Remove the EVAP Canister.




16. Disconnect the fuel feed, fuel return, and [1][2]EVAP pipe assemblies and the insulator clips from the fuel tank.




17. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.

INSTALLATION PROCEDURE




1. Reinstall the insulator pads on the fuel tank.




2. Connect the fuel feed, fuel return, and [1][2]EVAP pipe assemblies and the insulator clips.




3. Install the EVAP canister.




4. With the aid of an assistant, position and support the fuel tank.
5. Connect the [1][2]EVAP pipes to the rear of the fuel tank.
6. Connect the [1][2]EVAP pipe to the fuel limiter vent valve.
7. Connect the fuel filler [1][2]EVAP pipe at the rear of the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel tank retaining strap attaching bolts.

Tighten
Tighten the front fuel tank retaining strap bolts to 47 N.m (35 lb ft).




9. Connect the quick-connect fittings at the fuel tank.
10. Connect the [1][2]EVAP pipe at the front of the fuel tank.




11. Connect the fuel tank filler hose to the fuel tank.




12. Inspect and make sure tiller hose (4) is fully seated on fuel tank port (2).
13. Make sure clamp (1) is properly located on tank port between the bead (5) and tank (3).

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

14. Reinstall the rubber exhaust pipe hangers.
15. Inspect the fuel and [1][2]EVAP pipes making sure they were not kinked or damaged during removal and installation.
16. Lower the vehicle.
17. Reinstall the fuel sender assembly.
18. Add fuel and install the fuel tank filler pipe cap.
19. Connect the negative battery cable.
20. Inspect the fuel system for leaks by performing the following steps:
20.1. Turn the ignition switch ON position for 2 seconds.
20.2. Turn the ignition switch OFF for 10 seconds.
20.3. Turn the ignition switch ON.
20.4. Inspect for fuel leaks.