Fuel Tank Replacement (Long Wheel Base)

FUEL TANK REPLACEMENT (LONG WHEEL BASE)

REMOVAL PROCEDURE

NOTE: Refer to Nylon Fuel Lines Notice in Service Precautions.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Vehicle Lifting.
4. Disconnect the quick-connect fitting at the inlet side of the fuel filter.
5. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
6. Disconnect the quick connect fitting on the evaporative emission (EVAP) purge pipe, near the fuel filter.




7. Disconnect the vapor recirculation pipe from the filler tube.
8. Disconnect the fuel filler hose at the fuel tank.
9. Disconnect the fuel tank harness at the body pass through.




10. With the aid of an assistant, support the fuel tank.
11. Remove the fuel tank strap attaching bolts and lower the fuel tank straps.




12. Remove the fuel tank from the vehicle.
13. If the fuel tank is not being replaced, go to the installation procedure.

DISASSEMBLY PROCEDURE




1. Place the fuel tank in a suitable work area.
2. Remove the EVAP canister.
3. Remove the EVAP canister vent valve (2).
4. Remove the fuel sender assembly.
5. Remove the fuel feed (4) and fuel return (5) pipes from the fuel tank pipe clips.
6. Remove the EVAP purge pipe (8) from the fuel tank pipe clip.

ASSEMBLY PROCEDURE




1. Install the EVAP purge pipe (8) into the fuel tank clip.
2. Install the fuel feed (4) and fuel return (5) pipes into the fuel tank pipe clips.
3. Install the fuel sender assembly.
4. Install the EVAP canister vent valve (2).
5. Install the EVAP canister.

INSTALLATION PROCEDURE




1. With the aid of an assistant, position and support the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.




2. Install the fuel tank straps.

Tighten
Tighten the fuel tank retaining straps bolts to 47.5 N.m (35 lb ft).

3. Connect the fuel tank harness at the body pass through.




4. Connect the vapor recirculation pipe to the filler tube.




5. Connect the fuel filler hose at the fuel tank.

Tighten
Tighten the fuel fill hose to 2.5 N.m (22 lb in).

6. Connect the quick connect fitting on the EVAP purge pipe, near the fuel filter.
7. Connect the quick-connect fitting on the fuel return pipe, near the fuel filter.
8. Connect the quick-connect fitting at the inlet side of the fuel filter.
9. Lower the vehicle.




10. Add fuel to the fuel tank.
11. Install the fuel filler cap.
12. Connect the negative battery cable.
13. Inspect for fuel 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.
13.4. Inspect the fuel system for fuel leaks.