Removal and Replacement

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 34730 Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench




1. Relieve the fuel system fuel pressure.
2. Drain the fuel tank (1).
3. Raise the vehicle.




4. Remove the exhaust system.
5. Remove the wheel house filler pipe (1) opening cover in order to gain access to the fuel tank filler pipe.
6. Remove the fuel tank filler pipe attaching screw (2).




7. Remove the fuel tank filler pipe (1) hose clamps and the fuel tank filler pipe.
8. Remove the fuel feed, fuel return and vapor pipes near the fuel filter.
9. Remove the [1][2]EVAP pipes and retainers at the evaporative emission canister.
10. Remove the rear suspension support assembly.
11. Remove the fuel tank electrical connectors.
12. Remove the fuel tank bolts (3) from the fuel tank (2) straps.
13. 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 Installation Procedure.
2. Disassemble the harness retaining straps (2).
3. Disassemble the fuel feed, fuel return, and [1][2]EVAP hoses.
4. Disassemble the fuel sender assembly.





ASSEMBLE PROCEDURE
1. Assemble the fuel sender assembly.
2. Assemble the fuel feed, fuel return, and [1][2]EVAP hoses.
3. Assemble the harness retaining straps (2).
4. Assemble the fuel tank filler pipe and fuel tank filler pipe clamps.





INSTALLATION PROCEDURE

NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.
1. Position and support the fuel tank (4) with the aid of an assistant.

NOTE: Refer to Fastener Notice in Cautions and Notices.

2. Install the fuel tank straps (2).

Tighten
Tighten the fuel tank strap bolts (3). Tighten the bolts to 48 N.m (35 lb ft).

3. Install the rear suspension support assembly bolts and the lower suspension support assembly.
4. Install the fuel tank electrical connectors.
5. Install the [1][2]EVAP pipes and retainers at the evaporative emission canister.
6. Install the fuel feed, fuel return, and vapor pipes near the fuel filter.
7. Install the fuel tank filler pipe clamps and the fuel tank filler pipe.

Tighten
Tighten the fuel tank filler pipe clamps to 3 N.m (27 lb in).

8. Install the fuel tank filler pipe (1) attaching screw (2).

Tighten
Tighten the fuel tank filler pipe clamps to 8 N.m (71 lb in).

9. Install the wheel house filler pipe opening cover.
10. Install the exhaust system.
11. Lower the vehicle.
12. Add fuel and install the fuel tank filler pipe (1) cap.
13. Install the negative battery cable.
14. Inspect for leaks.
14.1. Turn the ignition switch ON for 2 seconds.
14.2. Turn the ignition switch OFF for 10 seconds.
14.3. Turn the ignition switch ON.
14.4. Check for fuel leaks.