Fuel Tank Removal and Installation (Short Wheel Base)

Fuel Tank Replacement (Short Wheel Base)

Removal Procedure

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




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Disconnect the fuel feed pipe (1) quick connect fitting.
5. Disconnect the evaporative emission (EVAP) pipe quick connect fitting.




6. Disconnect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting from the fuel tank vapor recirculation hose (3).
7. Loosen the fuel fill hose clamp (5) at the fuel tank.
8. Remove the fuel fill hose from the fuel tank (4).




9. Disconnect the fuel tank wiring harness (2) electrical connector from the body wiring harness pass-through.
10. Remove the fuel tank wiring harness from the electric brake harness clips (1).




11. Center an adjustable jack under the fuel tank.
12. Remove the EVAP canister nut (1).




13. Remove the fuel tank strap bolts (2), and reposition the fuel tank straps (1).
14. With the aid of an assistant, support and lower the fuel tank (3).
15. Remove the fuel tank from the adjustable jack and place on a suitable work surface.
16. If the fuel tank is not being replaced, proceed to the installation procedure.

Disassembly Procedure




1. Remove the EVAP canister (1).
2. Disconnect the fuel feed pipe quick-connect fitting.
3. Remove the fuel feed pipe (5).
4. Remove the EVAP canister vent solenoid (2).
5. Remove the EVAP pipe assembly.
6. Remove the fuel tank module (3).

Assembly Procedure




1. Install the fuel tank module (3).
2. Install the EVAP pipe assembly.
3. Install the fuel feed pipe (5).
4. Install the EVAP canister vent solenoid (2).
5. Connect the fuel feed pipe quick-connect fitting.
6. Install the EVAP canister.

Installation Procedure




1. With the aid of an assistant, remove the fuel tank from the work surface and place on the adjustable jack.
2. With the aid of the assistant, support and install the fuel tank.

Notice: Refer to Fastener Notice.

3. Position the fuel tank straps (1) and install the strap bolts (2).

Tighten the bolts to 47 N.m (35 lb ft).

4. Remove the adjustable jack.




5. Install the EVAP canister nut (1).

Tighten the nut to 9 N.m (80 lb ft).




6. Connect the fuel tank wiring harness (2) electrical connector to the body wiring harness pass-through.
7. Install the fuel tank wiring harness to the electric brake harness clips (1).




8. Install the fuel fill hose to the fuel tank (4).
9. Tighten the fuel fill hose clamp (5) at the fuel tank.

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

10. Connect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting to the fuel tank vapor recirculation hose (3).




11. Connect the EVAP pipe quick connect fitting.
12. Connect the fuel feed pipe (1) quick connect fitting.
13. Lower the vehicle.
14. Add fuel to the fuel tank.
15. Install the fuel fill cap.
16. Connect the negative battery cable.
17. Inspect for fuel leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect the fuel system for fuel leaks.

18. Install the intake manifold cover.