Fuel Tank Replacement
REMOVAL PROCEDURECAUTION:
^ Refer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.
^ Refer to Safety Goggles and Fuel Caution in Cautions and Notices.
^ Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
^ Use forced air ventilation such as a fan set outside of the trunk.
^ Plug or cap any fuel system openings in order to reduce fuel vapor formation.
^ Clean up any spilled fuel immediately.
^ Avoid sparks and any source of ignition.
^ Use signs to alert others in the work area that fuel system work is in process.
NOTE: The fuel tank equipped with ORVR components require special handling. Follow all instructions for servicing the fuel tank as specified in the service procedures. Damage to the fuel system components and the failure to meet the Federal Regulations may result from incorrect servicing of the fuel tank.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the rear seat cushion from the vehicle.
4. Disconnect the fuel pump, the fuel level sensor (fuel gauge sending unit),and the fuel tank pressure sensor electrical connectors (2).
5. Push the electrical connectors through the grommet (1) in the floor of the vehicle.
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Remove the muffler and exhaust pipe assembly.
8. Remove the one clamp and the fuel filler hose (2) from the fuel tank filler neck.
9. Remove the one clamp and the fuel breather hose (3) from the fuel tank breather neck.
10. Remove the one clamp and the EVAP canister air inlet hose (4) from the EVAP canister air inlet pipe (if equipped).
11. Remove the two bolts (2) from the two parking brake cable brackets on the vehicle underbody and move the cable aside.
12. Remove the one clamp and the EVAP canister vapor hose (1) from the EVAP canister vapor pipe (3).
13. Disconnect the fuel feed quick connect line (2) from the fuel feed pipe (1).
14. Disconnect the fuel return quick connect line (3) from the fuel return pipe (4).
15. Remove the five fuel tank mounting bolts and the fuel tank from the vehicle underbody.
INSTALLATION PROCEDURE
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the fuel tank to the vehicle underbody and secure with the five mounting bolts.
Tighten
Tighten the fuel tank mounting bolts to 25 N.m (18 lb ft).
3. Connect the fuel feed quick connect line (2) to the fuel feed pipe (1).
4. Connect the fuel return quick connect line (3) to the fuel return pipe (4).
5. Connect the EVAP canister vapor hose (1) to the EVAP canister vapor pipe (2) and secure with the clamp.
6. Align the parking brake cable brackets and secure with the two bolts (2) to the vehicle underbody.
Tighten
Tighten the parking brake cable bracket bolt to 15 N.m (11 lb ft).
7. Connect the EVAP canister air inlet hose (4) to the EVAP canister air inlet pipe (if equipped) and secure with the clamp.
8. Connect the fuel breather hose (3) to the fuel tank breather neck and secure with the clamp.
9. Connect the fuel filler hose (2) to the fuel tank filler neck and secure with the clamp.
10. Push the fuel pump, the fuel level sensor, and the fuel tank pressure sensor electrical connectors up through the grommet in the vehicle floor.
11. Install the muffler and exhaust pipe assembly.
12. Lower the vehicle.
13. Connect the fuel pump, the fuel level sensor, and the fuel tank pressure sensor electrical connectors (2).
14. Install the rear seat cushion to the vehicle.
15. Refill the fuel tank.
16. Connect the negative battery cable.
Tighten
Tighten the negative battery cable terminal retainer to 5.5 N.m (49 lb in).
17. Turn ON the ignition in order to pressurize the fuel system.
18. Turn OFF the ignition.
19. Inspect for fuel leaks and repair as necessary.