Fuel Tank Replacement (Front Tank)

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the fuel tank filler housing to body screws (1), and retainer (2).




3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
4. Remove the fuel tank filler housing.




5. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Front Tank)Fuel Tank Draining Procedure (Rear Tank).
6. Disconnect the EVAP vent pipe (3) from the EVAP canister clip.
7. Remove the evaporative emission (EVAP) canister.




8. Loosen the vent hose clamp at the front tank.
9. Remove the vent hose from the front tank.




10. Loosen the fuel tank fill hose clamp.
11. Remove the fuel tank fill hose from the front tank.




12. Remove the fuel tank shield bolts.
13. Remove the fuel tank shield.




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

NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

15. Remove the fuel tank strap bolts.
16. Remove the fuel tank straps.
17. With the aid of an assistant, carefully lower the fuel tank slightly.




18. Remove the sending unit shield nuts.
19. Remove the sending unit shield.




20. Disconnect the fuel feed, return, and EVAP pipes from the sending unit.




21. Disconnect the sending unit electrical connector (2).
22. Remove the fuel tank.
23. Place the fuel tank in a suitable work area.
24. Disconnect the EVAP pipe from the fuel tank roll over valve and retaining clip.
25. If necessary, remove the sending unit.
26. 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. Connect the EVAP pipe to the fuel tank roll over valve and retaining clip.
4. Place the fuel tank onto a suitable jack.
5. With the aid of an assistant, partially raise the fuel tank.
6. Connect the sending unit electrical connector (2).




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




8. Install the sending unit shield.

NOTE: Refer to Fastener Notice in Service Precautions.

9. 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. Install the fuel tank shield.
15. Install the fuel tank shield bolts.

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




16. Install the fuel tank fill hose to the front tank.
17. Tighten the fuel tank fill hose clamp.

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




18. Install the vent hose to the front tank.
19. Tighten the vent hose clamp at the front tank.

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




20. Install the EVAP canister.
21. Connect the EVAP vent pipe (3) to the EVAP canister clip.




22. Install the fuel tank filler housing.
23. Install the fuel tank filler housing to the fuel tank fill pipe screws.

Tighten
Tighten the screws to 2.3 N.m (20 lb in).




24. Install the fuel tank filler housing to body screws (1), and retainer (2).

Tighten
Tighten the screws to 2.3 N.m (20 lb in).

25. Lower the vehicle.
26. Refill the fuel tank.
27. Install the fuel fill cap.
28. Connect the negative battery cable.
29. Use the following procedure in order to inspect for leaks:
29.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
29.2. Turn the ignition OFF for 10 seconds.
29.3. Turn the ignition ON, with the engine OFF.
29.4. Inspect for fuel leaks.