Removal and Installation

Standard Emission System:

Enhanced Evaporative Emissions:

REMOVAL

1. Relieve fuel system pressure.

WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.

FUEL SUPPLY TUBES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM OR POSSIBLE PERSONAL INJURY MAY OCCUR. REFER TO FUEL PRESSURE RELEASE.

2. Drain fuel from the fuel tank.
3. Raise vehicle on hoist.
4. Remove screw retaining the fuel tank filler pipe retainer to the fuel tank flange.
5. For enhanced evaporative emission vehicles, disconnect vapor control valve assembly signal tube connection to fuel filler pipe signal tube.
6. Disconnect clamp at fuel tank connecting vent hose to fuel tank.
7. Place a safety support under the fuel tank. Take care not to deform fuel tank. Remove the bolts from the RH fuel tank support strap and LH fuel tank support strap. Swing the fuel tank support straps out of the way.
8. Partially remove the fuel tank and disconnect the fuel supply tube and electrical connector from the fuel pump, if required.
9. Remove fuel tank from the vehicle.

INSTALLATION

1. NOTE: If the fuel pump has been removed, the fuel pump gasket must be replaced.

2. Make sure evaporative emission valve is installed on the fuel tank top.
3. Connect all required fuel tube, fuel return tube, vapor vent and electrical connectors which will be inaccessible after the fuel tank is installed.
4. Replace or install all body mounted fuel tank shields.
5. Place fuel tank in its proper position under body.

NOTE: If required, tape hoses and wiring to fuel tank top, to verify they are correctly routed and will not be pinched between fuel tank and body.

6. Lubricate the fuel tank filler pipe with water based tire mounting lubricant. Install the fuel tank onto the filler pipe; then bring the fuel tank into final position. Take care not to deform fuel tank.
7. Position RH fuel tank support strap and LH fuel tank support strap and start the retaining bolt. Align fuel tank with the RH fuel tank support strap and LH fuel tank support strap.
8. Check the hoses and wiring mounted on the fuel tank top to make sure they are correctly routed and will not be pinched between the fuel tank and body.

CAUTION: Make sure fuel tank heat shields are installed and are positioned correctly on the fuel tank or possible damage may occur.

9. Tighten the fuel tank support strap retaining bolts to 30-40 Nm (22-29 lb-ft).
10. Reconnect the fuel hoses and tubes.
11. Tighten the vent tube clamp to 1.8-2.6Nm (16-23 lb-in).
12. Lower vehicle.
13. Replace fuel.
14. Check for leaks.