Fuel Tank Replacement

REMOVAL PROCEDURE

CAUTION:
^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions.
^ Refer to Safety Goggles and Fuel Caution in Service Precautions.
^ Refer to Actions to take when Working With Fuel in Service Precautions.

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, and the 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 the exhaust pipe assembly.




8. Remove the clamp and the fuel filler hose (2) from the fuel tank filler neck.
9. Remove the clamp and the fuel breather hose (3) from the fuel tank breather neck.
10. Remove the clamp and the air inlet hose (4) to the EVAP canister from the canister air inlet pipe, if necessary.




11. Remove the 2 bolts (2) from the 2 parking-brake cable brackets on the vehicle underbody. Move the cable to the side.
12. Remove the clamp and the EVAP canister vapor hose (1) from the EVAP canister vapor pipe (3).




13. Disconnect the quick connect line (2) from the fuel feed pipe(1).
14. Disconnect the quick connect line (3) from the fuel return pipe (4).
15. Remove the 5 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 Service Precautions.

2. Install the fuel tank to the vehicle underbody, and secure the tank with the 5 mounting bolts.

Tighten
Tighten the bolts to 25 N.m (18 lb ft).




3. Connect the quick connect line (2) to the fuel feed pipe (1).
4. Connect the 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). Secure the hose with the clamp.
6. Align the parking-brake cable brackets and secure the brackets to the vehicle underbody with the 2 bolts (2).

Tighten
Tighten the bolt to 15 N.m (11 lb ft).




7. Connect the EVAP canister inlet hose (4) to the EVAP canister inlet pipe, if equipped. Secure the hose with the clamp.
8. Connect the fuel breather hose (3) to the breather neck. Secure the hose with the clamp.
9. Connect the fuel filler hose (2) to the fuel tank filler neck. Secure the hose with the clamp.
10. Push the electrical connectors for the fuel pump, for the fuel level sensor, and for the fuel tank pressure sensor through the grommet in the vehicle floor.
11. Install the muffler and the exhaust pipe assembly.
12. Lower the vehicle.




13. Connect the electrical connectors (2) to the fuel pump, to the fuel level sensor, and to the fuel tank pressure sensor.
14. Install the rear seat cushion to the vehicle.
15. Refill the fuel tank.
16. Connect the negative battery cable.

Tighten
Tighten the 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 any leaks as necessary.