Fuel Tank Replacement Short Wheel Base

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.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Disconnect the fuel feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the evaporative emission (EVAP) pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .



6. 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 .
7. Loosen the fuel fill hose clamp (5) at the fuel tank.
8. Remove the fuel fill hose from the fuel tank (4).



9. Disconnect the fuel tank wiring harness (2) electrical connector from the body wiring harness pass-through.
10. Remove the fuel tank wiring harness from the electric brake harness clips (1).



11. Center an adjustable jack under the fuel tank.
12. Remove the EVAP canister nut (1).



13. Remove the fuel tank strap bolts (2), and reposition the fuel tank straps (1).
14. With the aid of an assistant, support and lower the fuel tank (3).
15. Remove the fuel tank from the adjustable jack and place on a suitable work surface.
16. If the fuel tank is not being replaced, proceed to the installation procedure.

1. Remove the EVAP canister (1). Refer to Evaporative Emission Canister Replacement .
2. Disconnect the fuel feed pipe quick-connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
3. Remove the fuel feed pipe (5).
4. Remove the EVAP canister vent solenoid (2).
5. Remove the EVAP pipe assembly.
6. Remove the fuel tank module (3). Refer to Fuel Tank Module Replacement .

1. Install the fuel tank module (3). Refer to Fuel Tank Module Replacement .
2. Install the EVAP pipe assembly.
3. Install the fuel feed pipe (5).
4. Install the EVAP canister vent solenoid (2).
5. Connect the fuel feed pipe quick-connect fitting . Refer to Plastic Collar Quick Connect Fitting Service .
6. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .

1. With the aid of an assistant, remove the fuel tank from the work surface and place on the adjustable jack.
2. With the aid of the assistant, support and install the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

3. Position the fuel tank straps (1) and install the strap bolts (2).

Tighten
Tighten the bolts to 47 N·m (35 lb ft).

4. Remove the adjustable jack.



5. Install the EVAP canister nut (1).

Tighten
Tighten the nut to 9 N·m (80 lb ft).




6. Connect the fuel tank wiring harness (2) electrical connector to the body wiring harness pass-through.
7. Install the fuel tank wiring harness to the electric brake harness clips (1).



8. Install the fuel fill hose to the fuel tank (4).
9. Tighten the fuel fill hose clamp (5) at the fuel tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).

10. 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 .



11. Connect the EVAP pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
12. Connect the fuel feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
13. Lower the vehicle.
14. Add fuel to the fuel tank.
15. Install the fuel fill cap.
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
17. 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.

18. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .

Fuel Tank Replacement Long Wheel Base

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.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Disconnect the fuel feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the evaporative emission (EVAP) pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .



6. 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 .
7. Loosen the fuel fill hose clamp at the fuel tank.
8. Remove the fuel fill hose from the fuel tank (4).



9. Disconnect the fuel tank wiring harness (1) electrical connector from the body wiring harness pass-through.



10. Center an adjustable jack under the fuel tank.
11. Remove the fuel tank shield.
12. Remove the fuel tank strap bolts (2), and reposition the fuel tank straps (1).
13. With the aid of an assistant, support and lower the fuel tank (3).
14. Remove the fuel tank from the adjustable jack and place on a suitable work surface.
15. If the fuel tank is not being replaced, proceed to the installation procedure.

1. Remove the EVAP canister (2). Refer to Evaporative Emission Canister Replacement .
2. Remove the EVAP canister vent valve (3). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
3. Remove the fuel tank module (4). Refer to Fuel Tank Module Replacement .
4. Remove the fuel feed pipe (1) from the fuel tank pipe clips.
5. Remove the EVAP purge pipe (6) from the fuel tank pipe clip.

1. Install the EVAP purge pipe (6) into the fuel tank clip.
2. Install the fuel feed pipe (1) into the fuel tank pipe clips.
3. Install the fuel tank module (4). Refer to Fuel Tank Module Replacement .
4. Install the EVAP canister vent valve (3). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
5. Install the EVAP canister (2). Refer to Evaporative Emission Canister Replacement .

1. Remove the fuel tank from the work surface and place on the adjustable jack.
2. Support and install the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

3. Position the fuel tank straps (1) and install the strap bolts (2).

Tighten
Tighten the bolts to 47 N·m (35 lb ft).

4. Remove the adjustable jack.
5. Install the fuel tank shield.



6. Connect the fuel tank wiring harness (1) electrical connector to the body wiring harness pass-through.



7. Install the fuel fill hose to the fuel tank (4).
8. Tighten the fuel fill hose clamp at the fuel tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).

9. 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 .



10. Connect the EVAP pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
11. Connect the fuel feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
12. Lower the vehicle.
13. Add fuel to the fuel tank.
14. Install the fuel fill cap.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
16. 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.

17. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .