Fuel Tank Replacement

REMOVAL PROCEDURE

Tools Required
^ J 34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench
^ J 42960-1 Fuel Tank Drain Hose
^ J 42960-2 Fuel Flapper Door Holder

CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. Service and Repair
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the fuel fill pipe shield.




6. Remove the fuel tank fill pipe support bracket bolt.
7. Remove the exhaust system from the catalytic converter back.
8. Remove the exhaust pipe heat shield and the exhaust muffler heat shield.




9. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
10. Disconnect the fuel return pipe (2) at the rear quick-connect fitting.
11. Disconnect the EVAP purge pipe (1) at the rear quick-connect fitting.




12. Disconnect the fuel feed pipe at the fuel filter inlet.
13. Cap the fuel pipes in order to prevent possible fuel system contamination.




14. Remove the rear pipe clip.




15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.




17. Disconnect the hose from the EVAP canister vent solenoid.
18. Remove the EVAP canister vent solenoid from the fuel tank bracket.




19. Disconnect the fill limiter vent valve pipe from the EVAP canister.
20. Carefully bend the fuel tank bracket in order to remove the EVAP canister.




21. Disconnect the fuel feed pipe (4), the fuel return pipe (2), and the EVAP pipe (3) from the fuel sender.
22. Disconnect the EVAP pipe from the fill limiter vent valve pipe (10).
23. Remove the fuel and EVAP pipes from the fuel tank.
24. Disconnect the fuel sender electrical connectors (1).
25. Remove the fuel sender electrical harness (8) from the fuel tank.




26. Remove the fuel sender assembly from the fuel tank.




27. Remove the fuel fill hose to fuel tank clamp (1).
28. Remove the fuel fill pipe and hose from the fuel tank.

INSTALLATION PROCEDURE




1. Install the fuel fill pipe and hose to the fuel tank.

NOTE: Refer to the Fastener Notice in Service Precautions.

Tighten
Tighten the fuel fill hose clamp (1) to 2.5 N.m (22 lb in).




2. Install the fuel sender assembly to the fuel tank.
3. Perform the fuel tank leak check. Refer to Fuel Tank Leak Check.




4. Install the fuel sender electrical harness (8) to the fuel tank.
5. Connect the fuel sender electrical connectors (1).
6. Install the fuel feed pipe (4) and the fuel return pipe (2) to the fuel sender and the fuel tank clips.
7. Connect the EVAP pipe (3) to the fuel sender.
8. Connect the EVAP pipe to the fill limiter vent valve pipe (10).




9. Carefully bend the fuel tank bracket in order to install the EVAP canister.
10. Connect the fill limiter vent valve pipe to the EVAP canister.




11. Install the EVAP canister vent solenoid to the fuel tank bracket.
12. Connect the hose to the EVAP canister vent solenoid.




13. With the aid of an assistant, position and support the fuel tank.
14. Position the fuel tank straps up.
15. Install the fuel tank strap attaching bolts.

Tighten
Tighten the fuel tank strap attaching bolts to 33 N.m (24 lb ft).




16. Connect the fuel sender and the fuel pressure sensor electrical connectors at the pass through connector.




17. Remove the caps from the fuel pipes.
18. Connect the fuel feed pipe at the fuel filter inlet.




19. Connect the EVAP purge pipe (1) at the rear quick-connect fitting.
20. Connect the fuel return pipe (2) at the rear quick-connect fitting.




21. Install the fuel and EVAP pipes into the pipe clip.
22. Align the fuel and EVAP pipes into a flat position.
23. Install the pipe clip bolt.

Tighten
Tighten the pipe clip bolt to 5.5 N.m (49 lb in).




24. Install the fuel tank fill pipe support bracket bolt.

Tighten
Tighten the fuel tank fill pipe support bracket bolt to 10 N.m (89 lb in).

25. Install the exhaust system heat shields and attaching screws.
26. Install the exhaust system.




27. Install the fuel filler pipe shield.
28. Lower the vehicle.
29. Refill the fuel tank.
30. Install the fuel filler cap.
31. Connect the negative battery cable.
32. Inspect for leaks.
32.1. Turn ON the ignition for 2 seconds.
32.2. Turn OFF the ignition for 10 seconds.
32.3. Turn ON the ignition.
32.4. Check for fuel leaks.