Fuel Tank Replacement

WARNINGS:
- Provide additional support when a vehicle is on a hoist:
- Before removing pads, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal This helps avoid a tip-off.
- Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

CAUTIONS:
- Do not attempt to straighten the kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

- Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.

REMOVE OR DISCONNECT
1. Relieve the fuel system fuel pressure, refer to Fuel Pressure Release.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle.




4. Quick-Connect fitting at the inlet side of the in-pipe fuel filter, refer to Fuel Line Coupler.
5. Quick-Connect fitting on the fuel return pipe near the fuel filter.




6. Fuel tank [1][2]EVAP pipe quick-connect fitting at the EVAP pipe canister.
7. [1][2]EVAP fuel filler pipe from the side of the fuel tank.




8. Fuel tank filler pipe hose clamp.
9. Fuel tank filler pipe.




10. Fuel tank filler vent hose clamp.
11. Fuel tank filler vent hose at filler neck.




12. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.
13. Fuel sender electrical connector.
14. Fuel tank pressure sensor electrical connector.




15. Fuel tank from the vehicle and place the fuel tank in a suitable work area.
16. If the fuel tank is not being replaced, go to Install Or Connect / Step # 6
17. Fuel feed and return pipe quick-connect fittings.




18. Remove the fuel feed pipe.
19. Remove the fuel return pipe.




20. [1][2]EVAP pipe assembly.
21. Fuel sender assembly, refer to Fuel Tank Sender.

INSTALL OR CONNECT
1. Fuel sender assembly.
2. [1][2]EVAP pipe assembly.
3. Fuel feed pipe.
4. Fuel return pipe.
5. Quick-connect fittings at the fuel sender.
6. With the aid of an assistant, position and support the fuel tank.
7. Fuel sender electrical connector and retaining clips.
8. Fuel tank pressure sensor electrical connector.
9. Fuel tank retaining strap attaching bolts and tighten to 47.5 Nm (35 lb ft).
10. Fuel tank filler vent hose to the fuel tank and tighten hose clamp to 2.5 Nm (22 lb in).
11. Fuel tank filler pipe to the fuel tank and tighten clamp to 2.5 Nm (22 lb in).
12. Fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
13. Fuel return pipe quick-connect fitting near the fuel filter.
14. [1][2]EVAP fuel filler pipe to the side of the fuel tank.
15. Fuel tank [1][2]EVAP pipe quick-connect fitting at the EVAP canister.
16. Lower the vehicle.




17. Add fuel and install the fuel tank filler pipe cap.
18. Negative battery cable.
19. Inspect for leaks:
a. Turn the ignition switch to the ON position for 2 seconds.
b. Turn the ignition switch to the OFF for 10 seconds.
c. Turn the ignition switch to the ON position.
d. Check for fuel leaks.