Fuel Tank Replacement

REMOVAL PROCEDURE

NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

IMPORTANT: Always maintain cleanliness when servicing the 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.
4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).




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




6. Disconnect the fuel feed and return pipes at the fuel filter and fuel filter area.
7. Disconnect the evaporative emission (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. Separate the two halves of the EVAP fresh air hose at the splice.




10. Remove the fuel tank shield push pins (2).
11. Remove the fuel tank shield (3).

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions.




12. With the aid of an assistant, support the fuel tank (1), and remove the fuel tank strap attaching bolts (2) from the fuel tank straps (3).
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 Fuel Tank Installation Procedure.
16. Remove the EVAP canister.
17. Remove the fuel feed, fuel return, and EVAP pipe assemblies.
18. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.

INSTALLATION PROCEDURE




1. Install the insulator pad on the fuel tank.

NOTE: Refer to Nylon Pipes Notice in Service Precautions.

2. Install the fuel feed, the fuel return, and the EVAP pipe assemblies.
3. Install the EVAP canister.




4. With the aid of an assistant, position and support the fuel tank (1).

NOTE: Refer to Fastener Notice in Service Precautions.

5. Install the fuel tank retaining strap bolts (2).

Tighten
Tighten the bolts to 48 N.m (35 lb ft).




6. Install the fuel tank shield (3).
7. Install the fuel tank shield push pins (2).




8. Connect the quick-connect fittings at the fuel filter and fuel filter area.
9. Connect the EVAP pipe at the front of the fuel tank.




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




11. Connect the two parts of the EVAP fresh air hose at the splice.




12. Fully seat the filler hose (4) on the fuel tank port (2).
13. Make sure the clamp (1) is properly located on the 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. Install the rubber exhaust pipe hangers.
15. Lower the vehicle.
16. Install the fuel sender assembly.
17. Add fuel and install the fuel filler pipe cap.
18. Connect the negative battery cable.
19. Inspect for fuel leaks using the following procedure:
19.1. Turn ON the ignition, for 2 seconds.
19.2. Turn OFF the ignition, for 10 seconds.
19.3. Turn ON the ignition.
19.4. Inspect for fuel leaks.