Removal and Replacement

REMOVAL PROCEDURE

NOTE: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

IMPORTANT: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace the pipes.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.
4. Disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter.
5. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.




6. Disconnect the fuel tank [1][2]EVAP pipe quick-connect fitting at the EVAP pipe canister.
7. Remove the [1][2]EVAP fuel filler pipe from the side of the fuel tank.




8. Loosen the fuel tank filler pipe hose clamp.
9. Remove the fuel tank filler pipe.




10. Loosen the fuel tank filler vent hose clamp.
11. Remove the fuel tank filler vent hose at the filler neck.




12. With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts.
13. Disconnect the fuel sender electrical connector.
14. Disconnect the fuel tank pressure sensor electrical connector.




15. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
16. If the fuel tank is not being replaced, go to the Installation Procedure.




17. Disconnect the fuel feed and return pipe quick-connect fittings.
18. Remove the fuel feed pipe.
19. Remove the fuel return pipe.




20. Remove the [1][2]EVAP pipe assembly.
21. Remove the fuel sender assembly.

INSTALLATION PROCEDURE




1. Install the fuel sender assembly.
2. Install the [1][2]EVAP pipe assembly.




3. Install the fuel feed pipe.
4. Install the fuel return pipe.
5. Connect the quick-connect fittings at the fuel sender.




6. With the aid of an assistant, position and support the fuel tank.
7. Connect the fuel sender electrical connector and the fuel sender retaining clips.
8. Connect the fuel tank pressure sensor electrical connector.

NOTE: Refer to Fastener Notice in Service Precautions.




9. Install the fuel tank retaining strap attaching bolts.

Tighten
Tighten the fuel tank retaining strap bolts to 47.5 N.m (35 lb ft).




10. Connect the fuel tank filler vent hose to the fuel tank.

Tighten
Tighten the fuel tank filler vent hose clamp to 2.5 N.m (22 lb in).




11. Connect the fuel tank filler pipe to the fuel tank.

Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).




12. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
13. Connect the fuel return pipe quick-connect fitting near the fuel filter.
14. Connect the [1][2]EVAP fuel filler pipe to the side of the fuel tank.




15. Connect the fuel tank [1][2]EVAP pipe quick-connect fitting at the EVAP canister.




16. Lower the vehicle.
17. Add fuel and Install the fuel tank filler pipe cap.
18. Reconnect the negative battery cable.
19. Inspect for fuel leaks using the following procedure:
19.1. Turn ON the ignition, for 2 seconds.
19.2. Turn OFF the ignition, for 10 seconds.
19.3. Turn ON the ignition.
19.4. Inspect for fuel leaks.