Fuel Tank Removal and Installation (Long Wheel Base)

Fuel Tank Replacement (Long Wheel Base)

Removal Procedure

Notice: 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.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Disconnect the fuel feed pipe (1) quick connect fitting.
5. Disconnect the evaporative emission (EVAP) pipe quick connect fitting.




6. Disconnect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting from the fuel tank vapor recirculation hose (3).
7. Loosen the fuel fill hose clamp at the fuel tank.
8. Remove the fuel fill hose from the fuel tank (4).




9. Disconnect the fuel tank wiring harness (1) electrical connector from the body wiring harness pass-through.




10. Center an adjustable jack under the fuel tank.
11. Remove the fuel tank shield.
12. Remove the fuel tank strap bolts (2), and reposition the fuel tank straps (1).
13. With the aid of an assistant, support and lower the fuel tank (3).
14. Remove the fuel tank from the adjustable jack and place on a suitable work surface.
15. If the fuel tank is not being replaced, proceed to the installation procedure.

Disassembly Procedure




1. Remove the EVAP canister (2).
2. Remove the EVAP canister vent valve (3).
3. Remove the fuel tank module (4).
4. Remove the fuel feed pipe (1) from the fuel tank pipe clips.
5. Remove the EVAP purge pipe (6) from the fuel tank pipe clip.

Assembly Procedure




1. Install the EVAP purge pipe (6) into the fuel tank clip.
2. Install the fuel feed pipe (1) into the fuel tank pipe clips.
3. Install the fuel tank module (4).
4. Install the EVAP canister vent valve (3).
5. Install the EVAP canister (2).

Installation Procedure




1. Remove the fuel tank from the work surface and place on the adjustable jack.
2. Support and install the fuel tank.

Notice: Refer to Fastener Notice.

3. Position the fuel tank straps (1) and install the strap bolts (2).

Tighten the bolts to 47 N.m (35 lb ft).

4. Remove the adjustable jack.
5. Install the fuel tank shield.




6. Connect the fuel tank wiring harness (1) electrical connector to the body wiring harness pass-through.




7. Install the fuel fill hose to the fuel tank (4).
8. Tighten the fuel fill hose clamp at the fuel tank.

Tighten the clamp to 2.5 N.m (22 lb in).

9. Connect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting to the fuel tank vapor recirculation hose (3).




10. Connect the EVAP pipe quick connect fitting.
11. Connect the fuel feed pipe (1) quick connect fitting.
12. Lower the vehicle.
13. Add fuel to the fuel tank.
14. Install the fuel fill cap.
15. Connect the negative battery cable.
16. Inspect for fuel leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect the fuel system for fuel leaks.

17. Install the intake manifold cover.