Removal and Replacement

Fuel Tank Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
3. Drain the fuel tank. Refer to Fuel Tank Draining (Procedures).
4. Remove the fuel fill pipe from the fuel tank.
5. Disconnect the vent hose.
6. Disconnect the chassis fuel pipes.
7. Cap the fuel and evaporative emission (EVAP) pipes in order to prevent possible fuel system contamination.




8. Disconnect the EVAP vent pipe at the fuel canister.




9. Remove the fuel tank protective shield.




10. Support the fuel tank with a suitable jack.

Caution: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

11. Remove the fuel tank strap attaching bolts.
12. Remove the fuel tank straps.
13. Carefully lower the rear of the fuel tank slightly.




14. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel feed and EVAP pipes from the fuel sender and the retaining clips.
18. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement (Service and Repair).
19. Remove the EVAP pipe from the fuel tank roll over valves and the retaining clips.
20. Transfer parts as necessary.

Installation Procedure

1. Connect the EVAP pipe to the fuel tank roll over valves and the retaining clips.
2. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement (Service and Repair).
3. Connect the fuel feed and EVAP pipes to the fuel sender and the retaining clips.




4. Support and partially raise the fuel tank.
5. Connect the fuel sender and the fuel pressure sensor electrical connectors.




6. Fully raise the fuel tank.
7. Install the fuel tank straps.

Caution: Refer to Fastener Caution (Fastener Caution).

8. Install the fuel tank strap attaching bolts.

Tighten the bolts to 40 Nm (30 lb ft).




9. Connect the fuel fill hose and the vent hose to the tank.

* Tighten the fuel fill hose clamp to 2.5 Nm (22 lb in).
* Tighten the vent hose clamp to 2.5 Nm (22 lb in).




10. Connect the EVAP vent pipe to the fuel canister.
11. Connect the chassis fuel pipes.




12. Install the fuel tank protective shield.

Tighten fuel tank protective shield bolts to 25 Nm (18 lb ft).

13. Refill the fuel tank.
14. Install the fuel filler cap.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).
16. Use the following procedure in order to inspect for leaks:

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, with the engine OFF.
4. Inspect for fuel leaks.

17. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (Upper Intake Manifold Sight Shield Replacement).