Fuel Tank Replacement

Fuel Pump And Fuel Gauge Sending Unit Electrical Connectors:

Fuel Filler Hose And Fuel Breather Hose:

WARNING: In order to prevent personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.


Removal Procedure
1. Relieve the fuel system pressure. Refer to Fuel System Pressure Release.
2. Drain the fuel tank. Refer to Draining Fuel Tank.
3. Remove the rear seat cushion from the vehicle.
4. Disconnect the fuel pump, fuel level sensor (fuel gauge sending unit), and fuel tank pressure sensor electrical connectors.
5. Push electrical connectors through the grommet in the floor.
6. Raise and suitably support the vehicle.
7. Remove the one clamp and the fuel filler hose from the fuel filler neck.
8. Remove the one clamp and the fuel breather hose from the fuel filler neck.
9. Remove the one clamp and the fuel feed inlet hose from the fuel filter.
10. Remove the one clamp and the fuel return hose from the fuel return pipe.
11. Remove the one clamp and the fuel vapor hose from the fuel vapor pipe.
12. Remove the Four fuel tank mounting bolts and fuel tank from vehicle underbody.

Inspect
- Inspect the fuel pump assembly hose connections for signs of leaks, loose fittings, deterioration or damage.
- Inspect the fuel pump assembly and the fuel level sensor gaskets for signs of leaks.
- Inspect the fuel tank for signs of damage that may cause leaks.
- Clean or replace components/assemblies as required.

Disassembly Procedure
1. Remove the clamp and the fuel feed hose from fuel feed pipe on the fuel tank.
2. Remove the clamp and the fuel return hose from fuel return pipe on the fuel tank.
3. Remove the clamp and the fuel vapor hose from fuel vapor pipe on the fuel tank.
4. Remove the clamp and the fuel filler hose from the fuel tank.
5. Remove the clamp and the fuel breather hose from the fuel tank.
6. Remove the five screws and the fuel level sensor from the fuel tank.
7. Remove the seven screws and the fuel pump assembly including the fuel feed and fuel return pipes from the fuel tank.
8. Remove the twelve screws and the fuel cut valves with the fuel vapor separator assembly from the fuel tank.
9. Remove the one screw and the fuel return volume assembly from the fuel tank (If equipped with the EVAP Tank Pressure Control Solenoid Vacuum Valve).


Assembly Procedure
1. Connect the fuel filler hose to the fuel tank and secure with one clamp.
2. Connect the fuel breather hose to the fuel tank and secure with one clamp.
3. Install the fuel cut valves with the fuel vapor separator assembly to the fuel tank and secure with twelve screws.
4. Install the one screw and the fuel return volume assembly from the fuel tank (If equipped with the EVAP Tank Pressure Control Solenoid Vacuum Valve).
5. Install the fuel pump assembly including the fuel feed and the fuel return pipes to the fuel tank and secure with seven screws.
6. Install the fuel level sensor to the fuel tank and secure with five screws.
7. Connect the fuel vapor hose to the fuel vapor pipe on the fuel tank and secure with one clamp.
8. Connect the fuel return hose to the fuel return pipe on the fuel tank; secure with one clamp.
9. Connect the fuel feed hose to the fuel feed pipe on the fuel tank and secure with one clamp.


Installation Procedure
1. Install the fuel tank to the vehicle underbody and secure with four mounting bolts. Tighten the fuel tank mounting bolts to 25 Nm (18 lb. ft.).
2. Connect the fuel vapor hose to the fuel vapor pipe and secure with one clamp.
3. Connect the fuel return hose to the fuel return pipe and secure with one clamp.
4. Connect the fuel feed inlet hose to the fuel filter and secure with one clamp.
5. Connect the fuel breather hose to the fuel filler neck and secure with one clamp.
6. Connect the fuel filler hose to the fuel filler neck and secure with one clamp.
7. Push the fuel pump and the fuel level sensor electrical connectors up through the grommet in the floor.
8. Lower the vehicle.
9. Connect the fuel pump and the fuel level sensor electrical connectors.
10. Install the rear seat cushion to the vehicle.
11. Refill the fuel tank.
12. Connect the negative (-) battery cable. Tighten the negative (-) battery cable-to-negative (-) battery terminal retainer to 5.5 Nm (4 lb. ft.).
13. Turn ON the ignition in order to pressurize the fuel system.
14. Turn OFF the ignition.
15. Check for any fuel leaks and repair as necessary.