Fuel Tank Replacement

REMOVE OR DISCONNECT

WARNING: In order to avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.


CAUTION: Do Not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.

Fuel Tank Assembly:

1. Relieve the fuel system fuel pressure, refer to the Fuel Pressure Relief Procedure,
2. Drain the fuel tank. refer to Draining Fuel Tank
3. Raise the vehicle.
4. Remove the fuel tank filler pipe EVAP pipe from the fuel tank EVAP pipe.
5. Remove the fuel tank filler pipe from the fuel tank.
6. Remove the quick-connect fittings at the fuel tank, refer to Servicing Quick Connect Fittings.
7. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.

CAUTION: Do Not bend the fuel tank straps, as this may damage the fuel tank straps.

8. Remove the fuel tank strap attaching bolts which retain the fuel tank straps (1), and support the fuel tank with the aid of an assistant (2).
9. Lower the fuel tank enough in order to disconnect the fuel sender electrical connector and remove the fuel sender retaining clips.
10. Remove the EVAP pipe from the rear of the fuel tank.
11. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.


DISASSEMBLE PROCEDURE
1. If the fuel tank is not being replaced, go to INSTALL OR CONNECT.
2. Disassemble the fuel sender assembly, refer to Fuel Sender Assembly Service.

ASSEMBLE PROCEDURE
Assemble fuel sender assembly, refer to Fuel Sender

INSTALL OR CONNECT
3. Position and support the fuel tank, with the aid of an assistant.
2. Install the EVAP pipe to the rear of the fuel tank.
3. Install the fuel sender electrical connector.
4. Install the fuel sender retaining clips.
5. Install the fuel tank retaining strap attaching bolts (2).
- Tighten the fuel tank retaining strap bolts (2) to 40 Nm (30 lb. ft.).
6. Install the quick-connect fittings, refer to Servicing Quick Connect Fittings.
7. Install the fuel tank filler pipe EVAP pipe to the fuel tank.
- Tighten the fuel tank filler pipe EVAP pipe hose clamp to Nm (24.8 lb. in).
8. Install the fuel tank filler pipe to the fuel tank.
- Tighten the fuel tank filler pipe hose clamp to 2.8Nm (24.8 lb. in.).
9. Install the rubber exhaust pipe hangers.
10. Lower the vehicle.
11. Add fuel to the fuel tank.
12. Install the fuel tank filler pipe cap.
13. Install the negative battery cable.
- Turn the ignition switch ON for 2 seconds.
- Turn the ignition switch OFF for 10 seconds.
- Turn the ignition switch ON.
- Check for fuel leak.