Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.






REMOVAL

1. Depressurize fuel system using fuel injection pressure gauge, refer to Fuel Pressure Release Procedure. Service and Repair
2. Remove rear seat cushion.
3. Remove plastic grommet from floor pan.
4. Disconnect fuel pump module electrical connector.






5. Disconnect fuel and vapor return line from fuel pump module.

NOTE: To disconnect fuel lines from fuel pump module, compress tabs on both sides of each nylon push connect fitting and ease fuel line out of fuel pump module.

6. Raise vehicle on hoist.
7. Remove muffler.
8. Remove resonator and outlet pipe heat shields.
9. Disconnect fuel filter lines and remove fuel filter and base.
10. Loosen fuel tank filler pipe clamp at fuel tank.
11. Support fuel tank using a suitable hydraulic jack.
12. Remove two fuel tank support strap bolts.
13. Partially lower fuel tank to gain access to fuel tank filler pipe vent tube and disconnect fuel tank filler pipe vent tube and fuel tank filler pipe from fuel tank.
14. Drain fuel from fuel tank.
15. Disconnect fuel vapor tube from restrictor.
16. Remove fuel tank from vehicle.
17. Remove three retaining nuts and fuel tank shield from fuel tank.

INSTALLATION

NOTE: If fuel pump module has been removed, the O-rings seal must be replaced.

1. Before proceeding, check following items:
a. Leak check fuel pump module. If necessary, use fuel tank sender wrench to ensure that the fuel pump module is securely installed.
b. Ensure evaporative emission valves are installed completely on fuel tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after fuel tank is installed.

Inner Fuel Tank Filler Seal:

d. Ensure inner fuel tank filler seal is in correct position.
2. Install fuel tank shield onto fuel tank and secure with three nuts.
3. Raise fuel tank into position.
4. Connect fuel vapor tube to restrictor.

NOTE: Ensure that inner fuel tank filler seal does not become dislodged during installation of fuel tank filler pipe.

5. Connect fuel tank filler pipe vent tube and fuel tank filler pipe to fuel tank.
6. Position fuel tank support straps and install two bolts. Tighten bolts to 29-41 Nm (21-30 lb ft).
7. Install fuel filter and connect fuel filter lines.
8. Install resonator and outlet pipe heat shields.
9. Install fuel filter.
10. Lower vehicle.
11. Connect fuel and vapor return line to fuel pump module.
12. Connect fuel pump module electrical connector.
13. Install plastic grommet into floor pan.
14. Install rear seat cushion.
15. Replace fuel drained from fuel tank.
16. START engine and check all connections for leaks.