Fuel Tank Replacement Short Wheel Base
Removal Procedure
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.
- Relieve the fuel system fuel pressure. Refer
to
Fuel Pressure Relief
.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
.
- Disconnect the fuel feed pipe (1) quick connect fitting. Refer
to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the evaporative emission (EVAP) pipe quick connect fitting.
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the fuel fill pipe vapor recirculation
pipe (2) quick connect fitting from the fuel tank vapor recirculation hose (3).
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Loosen the fuel fill hose clamp (5) at the fuel tank.
- Remove the fuel fill hose from the fuel tank (4).
- Disconnect the fuel tank wiring harness (2)
electrical connector from the body wiring harness pass-through.
- Remove the fuel tank wiring harness from the electric brake harness clips (1).
- Center an adjustable jack under the fuel
tank.
- Remove the EVAP canister nut (1).
- Remove the fuel tank strap bolts (2),
and reposition the fuel tank straps (1).
- With the aid of an assistant, support and lower the fuel tank (3).
- Remove the fuel tank from the adjustable jack and place on a suitable
work surface.
- If the fuel tank is not being replaced, proceed to the installation procedure.
Disassembly Procedure
- Remove the EVAP canister (1). Refer
to
Evaporative Emission Canister Replacement
.
- Disconnect the fuel feed pipe quick-connect fitting. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Remove the fuel feed pipe (5).
- Remove the EVAP canister vent solenoid (2).
- Remove the EVAP pipe assembly.
- Remove the fuel tank module (3). Refer to
Fuel Tank Module Replacement
.
Assembly Procedure
- Install the fuel tank module (3).
Refer to
Fuel Tank Module Replacement
.
- Install the EVAP pipe assembly.
- Install the fuel feed pipe (5).
- Install the EVAP canister vent solenoid (2).
- Connect the fuel feed pipe quick-connect fitting . Refer to
Plastic Collar Quick Connect Fitting Service
.
- Install the EVAP canister. Refer to
Evaporative Emission Canister Replacement
.
Installation Procedure
- With the aid of an assistant, remove the
fuel tank from the work surface and place on the adjustable jack.
- With the aid of the assistant, support and install the fuel tank.
Notice: Refer to Fastener Notice in the Preface section.
- Position the fuel tank straps (1) and install the strap bolts (2).
Tighten
Tighten the bolts to 47 N·m (35 lb ft).
- Remove the adjustable jack.
- Install the EVAP canister nut (1).
Tighten
Tighten the nut to 9 N·m (80 lb ft).
- Connect the fuel tank wiring harness (2)
electrical connector to the body wiring harness pass-through.
- Install the fuel tank wiring harness to the electric brake harness clips (1).
- Install the fuel fill hose to the fuel tank (4).
- Tighten the fuel fill hose clamp (5) at the fuel tank.
Tighten
Tighten the clamp to 2.5 N·m (22 lb in).
- Connect the fuel fill pipe vapor recirculation pipe (2) quick connect
fitting to the fuel tank vapor recirculation hose (3). Refer to
Plastic Collar Quick Connect Fitting Service
.
- Connect the EVAP pipe quick connect fitting.
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Connect the fuel feed pipe (1) quick connect fitting. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Lower the vehicle.
- Add fuel to the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Inspect for fuel leaks using the following procedure:
17.1. | Turn ON the ignition, with the engine OFF for 2 seconds. |
17.2. | Turn OFF the ignition for 10 seconds. |
17.3. | Turn ON the ignition. |
17.4. | Inspect the fuel system for fuel leaks. |
- Install the intake manifold cover. Refer to
Intake Manifold Cover Replacement
.
Fuel Tank Replacement Long Wheel Base
Removal Procedure
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.
- Relieve the fuel system fuel pressure. Refer
to
Fuel Pressure Relief
.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
.
- Disconnect the fuel feed pipe (1) quick connect fitting. Refer
to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the evaporative emission (EVAP) pipe quick connect fitting.
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the fuel fill pipe vapor recirculation
pipe (2) quick connect fitting from the fuel tank vapor recirculation hose (3).
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Loosen the fuel fill hose clamp at the fuel tank.
- Remove the fuel fill hose from the fuel tank (4).
- Disconnect the fuel tank wiring harness (1)
electrical connector from the body wiring harness pass-through.
- Center an adjustable jack under the fuel
tank.
- Remove the fuel tank shield.
- Remove the fuel tank strap bolts (2), and reposition the fuel tank
straps (1).
- With the aid of an assistant, support and lower the fuel tank (3).
- Remove the fuel tank from the adjustable jack and place on a suitable
work surface.
- If the fuel tank is not being replaced, proceed to the installation procedure.
Disassembly Procedure
- Remove the EVAP canister (2). Refer
to
Evaporative Emission Canister Replacement
.
- Remove the EVAP canister vent valve (3). Refer to
Evaporative Emission Canister Vent Solenoid Valve Replacement
.
- Remove the fuel tank module (4). Refer to
Fuel Tank Module Replacement
.
- Remove the fuel feed pipe (1) from the fuel tank pipe clips.
- Remove the EVAP purge pipe (6) from the fuel tank pipe clip.
Assembly Procedure
- Install the EVAP purge pipe (6) into
the fuel tank clip.
- Install the fuel feed pipe (1) into the fuel tank pipe clips.
- Install the fuel tank module (4). Refer to
Fuel Tank Module Replacement
.
- Install the EVAP canister vent valve (3). Refer to
Evaporative Emission Canister Vent Solenoid Valve Replacement
.
- Install the EVAP canister (2). Refer to
Evaporative Emission Canister Replacement
.
Installation Procedure
- Remove the fuel tank from the work surface
and place on the adjustable jack.
- Support and install the fuel tank.
Notice: Refer to Fastener Notice in the Preface section.
- Position the fuel tank straps (1) and install the strap bolts (2).
Tighten
Tighten the bolts to 47 N·m (35 lb ft).
- Remove the adjustable jack.
- Install the fuel tank shield.
- Connect the fuel tank wiring harness (1)
electrical connector to the body wiring harness pass-through.
- Install the fuel fill hose to the fuel tank (4).
- Tighten the fuel fill hose clamp at the fuel tank.
Tighten
Tighten the clamp to 2.5 N·m (22 lb in).
- Connect the fuel fill pipe vapor recirculation pipe (2) quick connect
fitting to the fuel tank vapor recirculation hose (3). Refer to
Plastic Collar Quick Connect Fitting Service
.
- Connect the EVAP pipe quick connect fitting.
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Connect the fuel feed pipe (1) quick connect fitting. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Lower the vehicle.
- Add fuel to the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Inspect for fuel leaks using the following procedure:
16.1. | Turn ON the ignition, with the engine OFF for 2 seconds. |
16.2. | Turn OFF the ignition for 10 seconds. |
16.3. | Turn ON the ignition. |
16.4. | Inspect the fuel system for fuel leaks. |
- Install the intake manifold cover. Refer to
Intake Manifold Cover Replacement
.