Removal and Replacement
REMOVAL PROCEDURECAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.
3. Raise the vehicle and suitably support.
4. Grasp the nylon fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel pipe quick-connect fitting.
CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.
5. Using compressed air, blow out dirt from the quick-connect fittings at end of the fuel pipes.
6. Disconnect the quick-connect fitting at the fuel filter.
7. Remove the quick connect fittings at the end of the fuel pipe and vapor pipes.
8. Remove the muffler support bolts.
9. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear suspension.
10. Remove the heat shield.
11. Remove the hoses at tank from filler, vent, and vapor pipes.
12. Disconnect the fuel tank electrical connector, at the body pass through connector.
13. With the aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.
14. With the aid of an assistant, lower the fuel tank.
15. Remove the fuel tank pressure sensor electrical connector.
16. Remove the fuel sender electrical connector.
17. Remove the tank from the vehicle.
18. Remove the fuel sender assembly from the tank.
INSTALLATION PROCEDURE
IMPORTANT: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel pipe O-rings for cuts, nicks, swelling, or distortion. Replace if necessary.
1. Install the fuel sender assembly to tank.
2. Install the fuel tank pressure sensor electrical connector.
3. Install the fuel tank sender electrical connector.
4. With the aid of an assistant, raise the fuel tank (1) to body.
5. Connect the fuel tank electrical connector, at the body pass through connector.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Install the fuel tank retaining straps.
Tighten
Tighten the bolts to 35 Nm (26 lb ft).
7. Install the hoses to filler, vent, and vapor pipes
8. Install the heat shield.
9. Install the exhaust rubber hangers.
NOTE: Refer to Fastener Notice in Service Precautions.
10. Install the muffler support bolts.
Tighten
Tighten the bolt to 15 Nm (11 lb ft).
CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings in order to reduce the risk of fire and personal injury.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
11. Install the nylon fuel pipe and fuel filter quick-connect fittings.
12. Lower the vehicle.
13. Refill the tank.
14. Connect the negative battery cable.
15. Inspect for fuel leaks through the following steps:
15.1. Turn the ignition switch to the ON position for two seconds.
15.2. Turn the ignition switch to the OFF position for ten seconds.
15.3. Turn the ignition switch to the ON position.
15.4. Check for fuel leaks.