Fuel Tank Replacement (Front Tank)
REMOVAL PROCEDURECAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
5. Remove the Evaporative Emission (EVAP) canister.
6. Disconnect the EVAP vent pipe (3) at the fuel tank clips (5).
7. Loosen the vent hose clamp (7).
8. Disconnect the vent hose (6) from the fuel tank.
9. With the aid of an assistant, support the fuel tank.
NOTE: Refer to Fuel Tank Straps Notice in Cautions and Notices.
10. Remove the fuel tank strap attaching bolts.
11. Remove the fuel tank straps.
12. Carefully lower the rear of the fuel tank slightly.
13. Remove the fuel sender cover.
14. Disconnect the fuel feed return and EVAP (1), (2), (3) at the fuel sender.
15. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.
18. Remove the fuel feed and return pipes (3) from the fuel sender and the retaining clips.
19. Remove the fuel sender assembly from the fuel tank.
20. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
INSTALLATION PROCEDURE
1. Connect the EVAP pipe to the fuel tank roll over valves (2), (4) and the retaining clips (1).
2. Install the fuel sender assembly to the fuel tank.
3. Connect the fuel feed and return pipes (3) to the fuel sender and the retaining clips.
4. With the aid of an assistant, support and partially raise the fuel tank front end first.
5. Connect the fuel sender and the fuel pressure sensor electrical connectors.
6. Connect the rear fuel tank to front fuel tank fuel feed pipe (2).
7. Install the fuel sender cover.
8. Fully raise the fuel tank.
9. Install the fuel tank straps.
NOTE: Refer to Fastener Notice in Cautions and Notices.
10. Install the fuel tank strap attaching bolts.
Tighten
Tighten the bolts to 40 N.m (30 lb ft).
11. Connect the vent hose (6) to the fuel tank.
Tighten
Tighten the vent hose clamp (7) to 2.5 N.m (22 lb in)
12. Connect the fuel fill hose (2) to the fuel tank.
Tighten
Tighten the fuel fill hose clamp (1) to 2.5 N.m (22 lb in)
13. Connect the EVAP vent pipe to the fuel tank clip (5).
14. Remove the caps from the fuel and EVAP pipes.
15. Connect the chassis fuel pipes (2) at the fuel tank pipes (1).
16. Install the EVAP canister.
17. Lower the vehicle.
18. Refill the fuel tank.
19. Install the fuel filler cap.
20. Connect the negative battery cable.
21. Inspect for leaks.
21.1. Turn the ignition ON for 2 seconds.
21.2. Turn the ignition OFF for 10 seconds.
21.3. Turn the ignition ON.
21.4. Inspect for fuel leaks.