Replacement Procedure

1. Remove fuel filler cap to relieve any pressure in the fuel tank.





2. Remove rear seat bottom cushion by pushing the 2 cushion release buttons located under the front edge of the seat.





3. Disconnect electrical connectors (C304 and C399).

4. Start engine and let it run out of fuel, turn off ignition.

5. Remove fuel pump access cover and gently pull wire harness and grommet through the hole in the access cover.

6. Disconnect and plug fuel hoses (mark hoses for correct reinstallation).

* NOTICE
If fuel tank is more than 1/4 full, it must be drained to avoid possible spillage from fuel filler pipe and to reduce excessive weight while fuel tank is being removed and reinstalled.

7. Raise vehicle on lift.





8. Disconnect 6 mm hose from charcoal canister to purge control line.

9. Disconnect 10 mm hose from charcoal canister to canister drain cut valve.





10. Disconnect fuel filler hose from fuel filler pipe.

11. Disconnect fuel tank vent hose.

12. Disconnect 6 mm hoses from vapor separator lines on fuel filler pipe.





13. Disconnect electrical connector from Fuel Tank Pressure Sensor (FTPS).

14. Remove 6 mm boll securing FTPS to body.

15. Place transmission jack under fuel tank.

16. Remove (2) 10 mm bolts securing fuel tank straps to body.

17. Carefully lower fuel tank.

18. Remove FTPS from fuel tank vapor hose.





19. Carefully remove vent hose and bracket from FTPS. Discard old bracket and vent hose.

20. Install new bracket and vent hose onto FTPS and set aside.





21. Gently remove foam pad covering evap hoses and wires.

22. Remove old evap hoses and tubes and discard.





23. Install new campaign hoses, tubes and FTPS as illustrated.

24. Reinstall foam pad.

25. Carefully reinstall fuel tank being careful not to pinch any wires or hoses.

* NOTICE
Positioning the fuel filler and vent hoses on the fuel filler pipe before tank is fully installed will make installation easier.

26. Tighten fuel tank straps.





27. Install 6 mm bolt that secures FTPS to body.

28. Connect charcoal canister hoses.

29. Connect fuel filler and vent hoses.





* NOTICE
The hose from the FTPS to the vapor separator should be trimmed to correct length, and installed on the 6 mm pipe closest to the vent pipe.

30. Lower vehicle.

31. Reconnect fuel hoses.

32. Install wire harness and grommet back through fuel pump access cover.

33. Reinstall fuel pump access cover.

34. Reconnect C304 and C399.

35. Install rear seat cushion.

36. Refill fuel tank (if drained).

37. Install fuel filler cap.

38. Start vehicle and check for leaks.





39. Apply supplied campaign completion slicker to inside of fuel filler door as shown in photo.