Removal and Replacement
TOOLS REQUIREDJ 34730 Fuel Pressure Gauge J 39765 Fuel Sender Lock Nut Wrench
REMOVAL PROCEDURE
NOTE: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.
IMPORTANT: Do Not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.
1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief Procedure. Service and Repair
2. Drain the fuel tank (1). Refer to Fuel Tank Draining Procedure.
CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.
3. Raise the vehicle.
4. Remove the exhaust system.
5. Remove the wheel house filler pipe opening cover (2).
6. Remove the fuel tank filler pipe attaching bolt (4) from the ground wire strap (3).
7. Remove the fuel feed (4) and fuel return (1) pipes.
8. Remove the [1][2]EVAP pipe (2) from the evaporative emission canister.
9. Remove the rear suspension support assembly.
10. Remove the fuel tank electrical connector (1).
11. Remove the fuel tank bolts (4) from the fuel tank (2) straps.
12. Remove the fuel tank (5) from the vehicle and place the fuel tank in a suitable work area.
DISASSEMBLE PROCEDURE
1. If the fuel tank is not being replaced, go to Installation Procedure.
2. Disassemble the fuel tank straps (2).
3. Disassemble the fuel feed, fuel return, and [1][2]EVAP hoses.
4. Remove the fuel sender assembly.
5. Remove the fuel tank filler pipe assembly clamp (2) from the fuel tank filler pipe assembly (1).
6. Remove the fuel tank filler pipe assembly (1) from the fuel tank (3).
ASSEMBLE PROCEDURE
1. Install the fuel tank filler pipe (1) to the fuel tank (3).
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the fuel tank filler pipe assembly clamp (2) to the fuel tank filler pipe assembly (1).
Tighten
Tighten the clamp to 3.5 N.m (31 lb in).
3. Install the fuel sender assembly.
4. Assemble the fuel feed, fuel return, and [1][2]EVAP hoses.
5. Assemble the fuel tank straps (2).
INSTALLATION PROCEDURE
NOTE: Refer to Fuel System Ground Notice in Service Precautions.
1. Position and support the fuel tank (4) with the aid of an assistant.
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the fuel tank straps (2).
Tighten
Tighten the fuel tank strap bolts (4). Tighten the bolts to 42 N.m (31 lb ft).
3. Install the rear suspension support assembly bolts and the lower suspension support assembly.
4. Install the fuel tank electrical connector (1).
5. Install the [1][2]EVAP pipe (2) to the evaporative emission canister.
6. Install the fuel feed (4) and fuel return (1) pipes.
7. Install the fuel tank tiller pipe attaching bolt (4) to the ground wire strap (3).
Tighten
Tighten the fuel tank filler pipe attaching bolt to 9 N.m (80 lb in).
8. Install the exhaust system.
9. Lower the vehicle.
10. Add fuel to the fuel tank.
11. Install the fuel tank filler pipe cap.
12. Install the negative battery cable.
13. Inspect for leaks.
13.1. Turn the ignition ON for 2 seconds.
13.2. Turn the ignition OFF for 10 seconds.
13.3. Turn the ignition ON.
13.4. Check for fuel leaks.
14. Install the fuel injector sight shield.