Removal and Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE

IMPORTANT: Clean all the fuel feed/return and evaporative emission (EVAP) pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel/EVAP system contamination.




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




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




6. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
7. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




8. Remove the fuel tank ground strap bolt (3).
9. Remove the chassis harness ground strap (2) and fuel tank ground strap (4).




10. Loosen the fuel tank fill pipe clamp at the tank.
11. Remove the fuel tank fill pipe from the tank and vehicle.
12. Remove the evaporative emission (EVAP) canister.




13. If necessary, remove the fuel tank shield bolts.
14. Remove the fuel tank shield.




15. Remove the fuel feed/return pipes from the clip on the fuel tank.
16. Disconnect the fuel feed/return pipes from the fuel tank pipes.
17. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.
18. Place a suitable adjustable jack under the fuel tank.




19. Remove the fuel tank strap bolts.

NOTE: Refer to Fuel Tank Strap Fastener Notice in Service Precautions.

20. Remove the fuel tank straps.
21. Lower the fuel tank until the electrical connections are accessible.




22. Disconnect the fuel sending unit and pressure sensor electrical connectors (1).
23. Completely lower the fuel tank.
24. With the aid of an assistant, place the fuel tank in a suitable work area.




25. Disconnect and remove the fuel feed (3) and return (2) pipes from the sending unit and retaining clips.
26. Disconnect and remove the EVAP pipe (1) from the sending unit, roll over valve (3), and retaining clip.
27. If replacing the fuel tank, remove the sending unit.

INSTALLATION PROCEDURE




1. If the fuel tank was replaced, install the sending unit.
2. Install and connect the EVAP pipe (1) to the sending unit, roll over valve (3), and retaining clip.
3. Install and connect the fuel feed (3) and return (2) pipes to the sending unit and retaining clips.




4. With the aid of an assistant, place the fuel tank on the jack.
5. Raise the fuel tank until the electrical connections can be made.
6. Connect the fuel sending unit and pressure sensor electrical connectors (1).




7. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel tank strap bolts.

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




9. Remove the adjustable jack from under the fuel tank.
10. Remove the caps from the fuel and EVAP pipes.
11. Connect the fuel feed/return pipes to the fuel tank pipes.
12. Install the fuel feed/return pipes to the clip on the fuel tank.
13. Install the EVAP canister.




14. If necessary, install the fuel tank shield.
15. Install the fuel tank shield bolts.

Tighten
Tighten the bolts to 18 N.m (13 lb ft).




16. Install the fuel tank fill pipe to the vehicle and tank.
17. Tighten the fuel tank fill pipe clamp at the tank.

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




18. Install the chassis harness ground strap (2) and fuel tank ground strap (4).
19. Install the fuel tank ground strap bolt (3).

Tighten
Tighten the bolt to 9 N.m (80 lb in).

20. Lower the vehicle.




21. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.




22. Install the fuel tank filler housing.
23. Install the fuel tank filler housing to 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. Fill the fuel tank.
26. Inspect the fuel system for leaks using the following procedure:
26.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
26.2. Turn the ignition OFF for 10 seconds.
26.3. Turn the ignition ON, with the engine OFF.
26.4. Inspect for fuel leaks.