Fuel Tank Removal and/or Cleaning

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.

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

Caution: Important do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure
2. Drain the fuel tank. Refer to Draining Fuel Tank
3. Raise the vehicle.
4. Remove the in-pipe fuel filter attaching screws.
5. Remove the quick-connect fitting at the inlet side of the in-pipe fuel filter. Refer to Servicing Quick Connect Fittings.
6. Remove the Quick-Connect fitting on the fuel return pipe near the fuel filter.
7. Remove the fuel sender electrical connector.
8. Remove the EVAP hose at the fuel tank.
9. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.
10. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
11. If the fuel tank is not being replaced, go to Install or Connect.
12. Remove the fuel sender assembly. Refer to Fuel Sender Assembly
13. Remove the fuel feed pipe.
14. Remove the fuel return pipe.
15. Remove the EVAP hose assembly.
16. Remove the fuel tank filler pipe check-ball.
17. Inspect the check-ball for cracks and holes replace if needed.


Installation Procedure
1. Install the fuel sender assembly. Refer to Fuel Sender Assembly
2. Install the quick-connect fittings at the fuel sender. Refer to Servicing Quick Connect Fittings.
3. Install the fuel feed and fuel return pipe assemblies.
4. Install the EVAP pipe to the fuel sender assembly.







5. With the aid of an assistant, position and support the fuel tank.
6. Install the fuel sender electrical connector and the fuel sender retaining clips.
7. Install the fuel tank retaining strap attaching bolts. Tighten the front and rear fuel tank retaining strap bolts to 25 Nm (18 lb. ft.).
8. Install the fuel tank filler EVAP pipe to the fuel tank. Tighten the fuel tank filler pipe hose clamp to 2.5 Nm (22 lb. in.).
9. Install the fuel tank filler pipe to the fuel tank.Tighten the fuel tank filler pipe hose clamp to 2.5 Nm (22 lb. in.).
10. Lower the vehicle.
11. Add fuel and install the fuel tank filler pipe cap.
12. Install the negative battery cable.
13. Inspect for leaks:
13.1. Turn the ignition switch to the ON position for 2 seconds.
13.2. Turn the ignition switch to the OFF for 10 seconds.
13.3. Turn the ignition switch to the ON position.
13.4. Check for fuel leaks.