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.

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

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 quick-connect fitting at the inlet side of the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.



6. Disconnect the evaporative emission (EVAP) purge pipe (5) quick-connect fitting at the EVAP canister.



7. Disconnect the vapor recirculation pipe from the filler tube.



8. With the aid of an assistant, support the fuel tank.
9. Remove the fuel tank strap attaching bolts.
10. Disconnect the fuel sender and the fuel tank pressure (FTP) sensor electrical connectors at the body pass through.



11. Remove the fuel tank from the vehicle.
12. Place the fuel tank in a suitable work area.
13. If the fuel tank is not being replaced, go to the installation procedure.
14. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .



15. Disconnect the fuel feed and return pipe quick-connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .
16. Remove the fuel feed pipe (6).
17. Remove the fuel return pipe (7).
18. Remove the EVAP pipe assembly.
19. Remove the fuel sender assembly (3). Refer to Fuel Sender Assembly Replacement .

1. Install the fuel sender assembly (3). Refer to Fuel Sender Assembly Replacement .
2. Install the EVAP pipe assembly.
3. Install the fuel feed pipe (6).
4. Install the fuel return pipe (7).
5. Connect the quick-connect fittings at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
6. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .



7. With the aid of an assistant, position and support the fuel tank.
8. Connect the fuel sender and the FTP sensor electrical connectors at the body pass through.




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.

9. Install the fuel tank retaining strap attaching bolts.

Tighten
Tighten the fuel tank retaining strap bolts to 47.5 N·m (35 lb ft).




10. Connect the vapor recirculation pipe to the fuel fill pipe.



11. Connect 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).




12. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
13. Connect the fuel return pipe quick-connect fitting near the fuel filter.



14. Connect the EVAP purge pipe (5) quick-connect fitting at the EVAP canister.
15. Lower the vehicle.



16. Add fuel.
17. Install the fuel tank filler pipe cap.
18. Connect the negative battery cable.
19. Inspect for fuel leaks using the following procedure:

19.1.

Turn ON the ignition for 2 seconds.

19.2.

Turn OFF the ignition for 10 seconds.

19.3.

Turn ON the ignition.

19.4.

Inspect for fuel leaks.

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 the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the quick-connect fitting at the inlet side of the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
6. Disconnect the quick connect fitting on the evaporative emission (EVAP) purge pipe, near the fuel filter.



7. Disconnect the vapor recirculation pipe from the filler tube.
8. Disconnect the fuel filler hose at the fuel tank.
9. Disconnect the fuel tank harness at the body pass through.



10. With the aid of an assistant, support the fuel tank.
11. Remove the fuel tank strap attaching bolts and lower the fuel tank straps.



12. Remove the fuel tank from the vehicle.
13. If the fuel tank is not being replaced, go to the installation procedure.

1. Place the fuel tank in a suitable work area.
2. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .
3. Remove the EVAP canister vent valve (2). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
5. Remove the fuel feed (4) and fuel return (5) pipes from the fuel tank pipe clips.
6. Remove the EVAP purge pipe (8) from the fuel tank pipe clip.

1. Install the EVAP purge pipe (8) into the fuel tank clip.
2. Install the fuel feed (4) and fuel return (5) pipes into the fuel tank pipe clips.
3. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
4. Install the EVAP canister vent valve (2). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
5. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .

1. With the aid of an assistant, position and support the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the fuel tank straps.

Tighten
Tighten the fuel tank retaining straps bolts to 47.5 N·m (35 lb ft).

3. Connect the fuel tank harness at the body pass through.



4. Connect the vapor recirculation pipe to the filler tube.



5. Connect the fuel filler hose at the fuel tank.

Tighten
Tighten the fuel fill hose to 2.5 N·m (22 lb in).

6. Connect the quick connect fitting on the EVAP purge pipe, near the fuel filter.
7. Connect the quick-connect fitting on the fuel return pipe, near the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
8. Connect the quick-connect fitting at the inlet side of the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
9. Lower the vehicle.



10. Add fuel to the fuel tank.
11. Install the fuel filler cap.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
13. Inspect for fuel leaks using the following procedure:

13.1.

Turn ON the ignition, with the engine OFF for 2 seconds.

13.2.

Turn OFF the ignition for 10 seconds.

13.3.

Turn ON the ignition.

13.4.

Inspect the fuel system for fuel leaks.