Fuel Tank Replacement (Short Wheel Base)
FUEL TANK REPLACEMENT (SHORT WHEEL BASE)REMOVAL PROCEDURE
NOTE: Refer to Nylon Fuel Lines Notice in Service Precautions.
IMPORTANT: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace the pipes.
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. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
5. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
6. Disconnect the evaporative emission (EVAP) purge pipe (5) quick-connect fitting at the EVAP canister.
7. Disconnect the vapor recirculation pipe from the filler tube.
8. With the aid of an assistant, support the fuel tank.
9. Remove the fuel tank strap attaching bolts.
10. Disconnect the fuel sender and the fuel tank pressure (FTP) sensor electrical connectors at the body pass through.
11. Remove the fuel tank from the vehicle.
12. Place the fuel tank in a suitable work area.
13. If the fuel tank is not being replaced, go to the installation procedure.
14. Remove the EVAP canister.
15. Disconnect the fuel feed and return pipe quick-connect fittings.
16. Remove the fuel feed pipe (6).
17. Remove the fuel return pipe (7).
18. Remove the EVAP pipe assembly.
19. Remove the fuel sender assembly (3).
INSTALLATION PROCEDURE
1. Install the fuel sender assembly (3).
2. Install the EVAP pipe assembly.
3. Install the fuel feed pipe (6).
4. Install the fuel return pipe (7).
5. Connect the quick-connect fittings at the fuel sender.
6. Install the EVAP canister.
7. With the aid of an assistant, position and support the fuel tank.
8. Connect the fuel sender and the FTP sensor electrical connectors at the body pass through.
NOTE: Refer to Fastener Notice in Service Precautions.
9. Install the fuel tank retaining strap attaching bolts.
Tighten
Tighten the fuel tank retaining strap bolts to 47.5 N.m (35 lb ft).
10. Connect the vapor recirculation pipe to the fuel fill pipe.
11. Connect the fuel tank filler pipe to the fuel tank.
Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).
12. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
13. Connect the fuel return pipe quick-connect fitting near the fuel filter.
14. Connect the EVAP purge pipe (5) quick-connect fitting at the EVAP canister.
15. Lower the vehicle.
16. Add fuel.
17. Install the fuel tank filler pipe cap.
18. Connect the negative battery cable.
19. Inspect for fuel leaks using the following procedure:
19.1. Turn ON the ignition for 2 seconds.
19.2. Turn OFF the ignition for 10 seconds.
19.3. Turn ON the ignition.
19.4. Inspect for fuel leaks.