Removal Procedure
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief
.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Remove the frame brace. Refer to
Frame Brace Replacement
in Frame
and Underbody.
- Loosen the fuel hose clamp (1) at the fuel tank.
- Separate the fuel hose (2) from the fuel tank.
- Disconnect the fuel tank pressure sensor electrical
connector (3).
- Disconnect the evaporative emission (EVAP) vent valve electrical connector (2).
- Disconnect the fuel feed, return and EVAP pipes. Refer
to
Plastic Collar Quick Connect Fitting Service
.
- Cap the fuel and EVAP pipes in order to prevent possible fuel system
contamination.
- Remove propeller shaft. Refer to
Propeller Shaft Replacement
in Propeller
Shaft.
- With the aid of an assistant, support the fuel tank.
- Remove the fuel tank strap bolts (1).
- Remove the fuel tank straps (2).
- Carefully lower the fuel tank.
- Disconnect the fuel sender electrical connector (1).
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- If the fuel tank is not being replaced, go to the Installation Procedure.
Disassembly Procedure
- Remove the EVAP vent valve (1). Refer to
Evaporative Emission Canister Vent Solenoid Valve Replacement
.
- Remove the fuel filter (8). Refer to
Fuel Filter Replacement
.
- Disconnect the fuel feed and return pipes from the fuel sender (5).
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Remove the fuel feed and return pipes from the retaining clip (7).
- Remove the EVAP vent valve pipe.
- Disconnect the EVAP vapor pipe from the fill limiter vent valve (4),
and the front and rear rollover valves (2, 6). Refer to
Plastic Collar Quick Connect Fitting Service
.
- Remove the EVAP vapor pipes.
- Remove the fuel sender assembly (5) from the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Remove the EVAP canister (3). Refer to
Evaporative Emission Canister Replacement
.
Assembly Procedure
- Install the EVAP canister (3). Refer to
Evaporative Emission Canister Replacement
.
- Install the fuel sender assembly (5) to the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Connect the EVAP vapor pipe to the fill limiter vent valve (4)
and the front and rear rollover valve (2, 6). Refer to
Plastic Collar Quick Connect Fitting Service
.
- Install the EVAP vent valve pipe.
- Connect the fuel feed and return pipes to the fuel sender (5).
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Install the fuel feed and return pipes to the retaining clip (7).
- Install the fuel filter (8). Refer to
Fuel Filter Replacement
.
- Install the EVAP vent valve (1). Refer to
Evaporative Emission Canister Vent Solenoid Valve Replacement
.
Installation Procedure
- With the aid of an assistant, position and support
the fuel tank.
- Connect the fuel sender electrical connector (1).
- Install the fuel tank straps (2).
Notice: Refer to Fastener Notice in the Preface section.
- Install the fuel tank strap bolts (1).
Tighten
Tighten the bolts to 32 N·m (24 lb
ft).
- Install the propeller shaft. Refer to
Propeller Shaft Replacement
in
Propeller Shaft.
- Remove the caps from the fuel and EVAP pipes.
- Connect the fuel feed, return and EVAP pipes. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Connect the fuel tank pressure sensor electrical connector (3).
- Connect the EVAP vent valve electrical connector (2).
- Connect the fuel hose (2) to the fuel tank.
Tighten
Tighten the clamp (1) to 2.5 N·m
(22 lb in).
- Lower the vehicle.
- Refill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Inspect for leaks.
15.1. | Turn the ignition ON, with the engine OFF for 10 seconds. |
15.2. | Turn the ignition OFF for 10 seconds. |
15.3. | Turn the ignition ON, with the engine OFF. |
15.4. | Inspect for fuel leaks. |
- Install the frame brace. Refer to
Frame Brace Replacement
in Frame
and Underbody.
- Lower the vehicle.