Removal and Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle Lifting.
4. Loosen the filler neck hose clamp at the fuel tank.
5. Disconnect the fuel tank filler neck from the fuel tank.




6. Disconnect the fuel tank pipes (1) from the fuel feed (2) and fuel return (5) pipes.




7. Disconnect the EVAP purge pipe (4).




8. Disconnect the fuel sender electrical connector (2).
9. Support the fuel tank.




10. Remove the fuel tank strap bolts (3) and the fuel tank straps.
11. Remove the fuel tank.




12. Remove the fuel sender assembly (4).
13. Remove the EVAP canister (1).

INSTALLATION PROCEDURE
1. Install the fuel sender assembly (4).




2. Install the EVAP canister (1).

NOTE: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.




3. Install the fuel tank and the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the fuel tank strap bolts (3).

Tighten
Tighten the strap bolts to 35 Nm (26 lb ft).




5. Connect the fuel sender electrical connector (2).




6. Connect the EVAP purge pipe (4).




7. Connect the fuel tank pipes (1) to the fuel feed (2) and fuel return (5) pipes.
8. Connect the fuel tank filler neck to the fuel tank.
9. Lower the vehicle.
10. Refill the fuel tank.
11. Install the fuel tank filler cap.
12. Connect the negative battery cable.
If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
13. Inspect for leaks using the following procedure.
13.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
13.2. Turn OFF the ignition for 10 seconds.
13.3. Turn ON the ignition, with the engine off.
13.4. Inspect for fuel leaks.
14. Install the engine cover.