Caution: Provide additional support when a vehicle is on a hoist:

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.

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Important: Always maintain cleanliness when servicing fuel system components.

Important: Important do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the fuel tank filler EVAP hose from the fuel tank.
5. Disconnect the fuel tank filler hose from the fuel tank.
6. Disconnect the quick-connect fittings at the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
7. Disconnect the fuel tank harness at the passthrough connector.
8. Remove the EVAP pipe from the connection at the front of the fuel tank.
9. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
10. Remove the exhaust pipe heat shield bolts and the exhaust pipe heat shield.



11. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.
12. Lower the fuel tank enough in order to disconnect the fuel sender electrical connector and remove the fuel sender retaining clips.
13. Disconnect the EVAP pipe to the rear of the fuel tank.
14. Disconnect the EVAP pipe to the fuel sender assembly.
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. Remove the modular fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
18. Remove the retaining clip from the EVAP pipe. Note the position of the retaining clip for installation.
19. Remove the EVAP pipe from the insulator clips. Note the position of the EVAP pipe for installation.
20. Disconnect the quick-connect fittings at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service .
21. Remove the fuel feed and fuel return pipe assemblies and the insulator clips from the fuel tank.



22. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Notice: 

1. Install the insulator pads on the fuel tank.
2. Install the insulator clips.
3. Connect the quick-connect fittings at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service .
4. Connect the fuel feed and fuel return pipe assemblies.
5. Position the EVAP pipe on the insulator clips as noted during disassembly.
6. Install the retaining clip on the EVAP pipe.
7. Install the modular fuel sender assembly. Refer to Fuel Sender Assembly Replacement .



8. With the aid of an assistant, position and support the fuel tank.
9. Connect the EVAP pipe to the rear of the fuel tank.
10. Connect the EVAP pipe to the fuel sender assembly.
11. Connect the fuel sender electrical harness connector at the passthrough connector.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

12. Install the fuel tank retaining strap attaching bolts (4).

Tighten
Tighten the front and rear fuel tank retaining strap bolts (4) to 47 N·m (35 lb ft).

13. Connect the quick-connect fittings. Refer to Metal Collar Quick Connect Fitting Service .
14. Install the modular fuel sender, and the fuel tank pressure sensor electrical connectors.
15. Connect the EVAP pipe at the front of the fuel tank.



16. Install the fuel tank filler EVAP pipe to the fuel tank.

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

17. Install 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).

18. Install the heat shield and the heat shield attaching screws.
19. Install the rubber exhaust pipe hangers.
20. Lower the vehicle.
21. Add fuel and install the fuel tank filler pipe cap.
22. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
23. Inspect for leaks using the following procedure:

23.1.

Turn ON the ignition, for 2 seconds.

23.2.

Turn OFF the ignition, for 10 seconds.

23.3.

Turn ON the ignition.

23.4.

Inspect for fuel leaks.