Fuel Tank Assembly

Fuel Tank:

Fuel Filler Neck:

Removal Procedure

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

NOTE: If nylon fuel feed or return pipes become kinked and cannot be straightened, they must be replaced.

NOTE: Numbers in text refer to numbers in images.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Release.
2. Drain the fuel tank (4).
3. Raise the vehicle.
4. Remove the exhaust system.
5. Remove the wheel house filler pipe (1) opening cover in order to gain access to the fuel tank filler pipe.
6. Remove the fuel tank filler pipe attaching screws. (5)
7. Remove the fuel tank filler pipe hose clamps and the fuel tank filler pipe.
8. Remove the connectors at the compressor.
9. Remove the fuel feed, fuel return, and vapor pipes near the fuel filter.
10. Remove the EVAP pipes and retainers at the evaporative emission canister.
11. Remove the rear tie rod ends.
12. Remove the rear suspension support assembly bolts and the lower suspension support assembly.
13. Remove the fuel tank bolts (3) from the fuel tank (2) straps.
14. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.

Disassemble Procedure
1. If the fuel tank is not being replaced.
2. Disassemble the harness retaining straps (2).
3. Disassemble the fuel feed, fuel return, and EVAP hoses.
4. Disassemble the fuel sender assembly.

Assemble Procedure
1. Assemble the fuel sender assembly.
2. Assemble the fuel feed, fuel return, and EVAP hoses.
3. Assemble the harness retaining straps (2).
4. Assemble the fuel tank filler pipe and fuel tank filler pipe clamps.

Installation Procedure
1. Position and support the fuel tank (4) with the aid of an assistant.
2. Install the fuel tank straps (2). Tighten tighten the fuel tank strap bolts (3) to 48 Nm (35 lb ft).
3. Install the rear suspension support assembly bolts and the lower suspension support assembly. Tighten tighten the suspension support assembly bolts to 165 Nm (122 lb ft).
4. Install the rear tie rod ends.
5. Install the EVAP pipes and retainers at the evaporative emission canister.
6. Install the fuel feed, fuel return, and vapor pipes near the fuel filter.
7. Install the connectors at the compressor.
8. Install the fuel tank filler pipe hose clamps and the fuel tank filler pipe.
9. Install the fuel tank filler pipe attaching screws (5).
10. Install the wheel house filler pipe opening cover.
11. Install the exhaust system.
12. Lower the vehicle.
13. Add fuel and install the fuel tank filler pipe (1) cap.
14. Install the negative battery cable.
15. Inspect for leaks.

15.1. Turn the ignition switch to the On position for 2 seconds.
15.2. Turn the ignition switch to the Off for 10 seconds.
15.3. Turn the ignition switch to the On position.
15.4. Check for fuel leaks.