Fuel Tank Replacement (Front Tank)

Fuel Tank Replacement (Dual Tanks - Front)







REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
Fuel Pressure Release
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
Procedures
3. Remove the evaporative emission (EVAP) canister.
4. Disconnect the pipe from the fuel tank valve.
5. Loosen the vent hose clamp at the front tank.
6. Remove the vent hose from the front tank.







7. If equipped, remove the fuel tank shield bolts.
8. If equipped, remove the fuel tank shield.






9. Using an adjustable jack, support the fuel tank.

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

10. Remove the fuel tank strap bolts.
11. Remove the fuel tank straps.
12. With the aid of an assistant, carefully lower the fuel tank until the sending unit is accessible.







13. If equipped, remove the sending unit shield nuts.
14. If equipped, remove the sending unit shield.







15. Disconnect the fuel feed, return, and EVAP pipes from the sending unit.
16. Lower the fuel tank slightly.







17. Release the connector position assurance (CPA) retainer.
18. Disconnect the sending unit electrical connector (2).
19. Completely lower the fuel tank.
20. Place the fuel tank in a suitable work area.
21. If necessary, remove the sending unit.
22. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.







INSTALLATION PROCEDURE
1. Remove the caps from the fuel and EVAP pipes.
2. If necessary, install the sending unit.
3. Place the fuel tank onto a suitable jack.
4. With the aid of an assistant, partially raise the fuel tank.
5. Connect the sending unit electrical connector (2).
6. Install the CPA retainer.







7. Connect the fuel feed, return, and EVAP pipes to the sending unit.







8. If equipped, install the sending unit shield.

NOTE: Refer to Fastener Notice in Service Precautions Fastener Notice.

9. If equipped, install the sending unit shield nuts.

Tighten
Tighten the nuts to ........................................10 N.m (89 lb in).







10. With the aid of an assistant, completely raise the fuel tank.
11. Install the fuel tank straps.
12. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to ...................................40 N.m (30 lb ft).

13. Remove the adjustable jack from the fuel tank.







14. If equipped, install the fuel tank shield.
15. If equipped, install the fuel tank shield bolts.

Tighten
Tighten the bolts to ......................................15 N.m (11 lb ft).







16. Install the vent hose to the front tank.
17. Tighten the vent hose clamp at the front tank.

Tighten
Tighten the clamp to ............................................2.5 N.m (22 lb in).

18. Connect the pipe to the fuel tank valve.
19. Install the EVAP canister.
20. Lower the vehicle.
21. Refill the fuel tank.
22. Install the fuel fill cap.
23. Connect the negative battery cable.
24. Use the following procedure in order to inspect for leaks:
24.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
24.2. Turn the ignition OFF for 10 seconds.
24.3. Turn the ignition ON, with the engine OFF.
24.4. Inspect for fuel leaks.