Rollover Valve: Service and Repair

Removal

Warning
Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible. Drain the fuel from the fuel tank before removing the tank.

1. Disconnect negative battery cable.
2. Remove rear seat cushion.








3. Disconnect fuel delivery module and tank pressure sensor connectors.
4. Remove three screws attaching access cover.
5. Remove rubber grommet and wires from access cover.
6. Remove access cover.
7. Disconnect two fuel hose quick connectors from fuel -delivery module.
8. Raise vehicle.
9. Disconnect canister close valve connector.
10. Position a lifting device below center of fuel tank.
11. Disconnect two fuel hose quick connectors attached to fuel filter.
12. Disconnect fuel vapor hose attached to canister.
13. Loosen joint hose clamp attached to fuel tank.
14. Disconnect joint hose from fuel tank.
15. Remove two bolts attaching fuel tank straps and remove fuel tank straps.

Caution
Cover the open ports on the fuel tank with plastic caps or other available covers to avoid fuel vapor contaminating the work area.

16. Remove fuel tank from vehicle.





17. Remove four bolts attaching rollover valve and remove rollover valve from tank.

Installation
Warning
Fuel is explosive. When working on fuel system, make sure to supply adequate ventilation to the work area. Do not smoke, and keep sparks and open flames away.


1. Raise vehicle.





2. Install rollover valve to fuel tank.
3. Install and tighten four bolts for rollover valve.

Tightening torque: 7.7-12.2 ft lb (10.8-16.7 Nm)

4. Remove protective caps from fuel tank ports.
5. Place fuel tank on lifting device and carefully raise fuel tank assembly into correct position.
6. Reconnect canister close valve connector.
7. Reconnect joint hose to fuel tank and tighten clamp.





8. Reconnect two fuel hoses to fuel tank.

Notice: Push evaporative hose onto fuel tank fitting at least 1.0 inch (25 mm). Push fuel filler hoses onto fuel tank and filler pipes at least 1.4 inches (35 mm).

9. Install fuel tank straps and tighten two bolts.

Tightening torque: 32-44 ft lb (43-61 Nm)

10. Install insulator and tighten bolts.
11. Lower vehicle.





12. Reconnect two fuel hoses to fuel delivery module.
13. Install rubber grommet and wires onto access cover.





14. Install access cover and tighten three screws.

Tightening torque: 7.7-12.2 ft lb (10.8-16.7 Nm)

15. Reconnect two connections to fuel delivery module.
16. Position wires correctly and secure to floor with tape.
17. Reinstall rear seat cushion.
18. Reconnect negative battery cable.