Fuel Tank Replacement

Fuel Pump And Fuel Gauge Sending Unit Electrical Connectors:

Fuel Filler Hose And Fuel Breather Hose:

WARNING: To help avoid personal injury when the vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

- Relieve fuel system pressure. Refer to Fuel Pressure Release/Service and Repair. Service and Repair
- Drain fuel tank.

REMOVE OR DISCONNECT
1. Rear seat cushion from vehicle.
2. Fuel pump and fuel gage sending unit electrical connectors (refer to accompanying image).

- Push electrical connectors through grommet in floor.
- Raise and suitably support vehicle.

3. One clamp and fuel filler hose from fuel filler neck refer to accompanying image).
4. One clamp and fuel breather hose from fuel filler neck (refer to accompanying image).
5. One clamp and fuel feed inlet hose from fuel filter.
6. One clamp and fuel return hose from fuel return pipe.
7. One clamp and fuel vapor hose from fuel vapor pipe.
8. Four fuel tank mounting bolts and fuel tank from vehicle underbody.

INSPECT
1. Fuel pump assembly hose connections for signs of leaks, loose fittings, deterioration or damage.
2. Fuel pump assembly and fuel gage sending unit gaskets for signs of leaks.
3. Fuel tank for signs of damage that may cause leaks.

- Clean or replace components/assemblies as required.

DISASSEMBLE
1. One clamp and fuel feed hose from fuel feed pipe on tank.
2. One clamp and fuel return hose from fuel return pipe on tank.
3. One clamp and fuel vapor hose from fuel vapor pipe on tank.
4. One clamp and fuel filler hose from tank.
5. One clamp and fuel breather hose from tank.
6. Five screws and fuel gage sending unit from tank.
7. Seven screws and fuel pump assembly with fuel feed and fuel return pipes from tank.
8. Twelve screws and fuel cut valves and fuel vapor separator assembly from tank.

- If equipped with a Tank Pressure Control Solenoid Vacuum (TPC SV) valve, remove one screw and fuel return volume assembly from tank.

ASSEMBLE
1. One clamp and fuel filler hose to tank.
2. One clamp and fuel breather hose to tank.
3. Fuel cut valves and fuel vapor separator assembly to tank; secure with twelve screws.

- If equipped with a TPC SV valve, install one screw and fuel return volume assembly to tank.

4. Fuel pump assembly with fuel feed pipe and fuel return pipe to tank; secure with seven screws.
5. Fuel gage sending unit to tank; secure with five screws.
6. Fuel vapor hose to fuel vapor pipe on tank; secure with one clamp.
7. Fuel return hose to fuel return pipe on tank; secure with one clamp.
8. Fuel feed hose to fuel feed pipe on tank; secure with one clamp.

INSTALL OR CONNECT
1. Fuel tank to underbody; secure with four mounting bolts. Tighten fuel tank mounting bolts to 25 Nm (18 lb ft).
2. Fuel vapor hose to fuel vapor pipe; secure with one clamp.
3. Fuel return hose to fuel return pipe; secure with one clamp.
4. Fuel feed inlet hose to fuel filter; secure with one clamp.
5. Fuel breather hose to fuel filler neck; secure with one clamp.
6. Fuel filler hose to fuel filler neck; secure with one clamp.

- Push fuel pump and fuel gage sending unit electrical connectors up through grommet in floor.
- Lower vehicle.

7. Fuel pump and fuel gage sending unit electrical connectors.
8. Rear seat cushion to vehicle.

- Refill fuel tank.

9. Negative (-) battery cable. Tighten Negative (-) battery cable-to-negative (-) battery terminal.

AFTER REPAIR INSPECTION
Turn ignition switch to "ON," and then back to "LOCK" to pressurize the fuel system. Check for any fuel leaks.