Removal and Replacement

Fuel Tank Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Drain the fuel tank. Refer to Fuel Tank Draining.
4. Remove the fuel fill pipe from the fuel tank.
5. Disconnect the chassis fuel pipes at the fuel filter.
6. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.




7. Disconnect the EVAP vent pipe at the fuel canister.




8. Loosen the vent hose and filler hose clamp.
9. Disconnect the vent hose and filler hose from the pipe.
10. Remove the fuel tank protective shield.




11. With the aid of an assistant, support the fuel tank.

Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

12. Remove the fuel tank strap attaching bolts.
13. Remove the fuel tank straps.
14. Carefully lower the rear of the fuel tank slightly.




15. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.
18. Remove the fuel feed and return pipes from the fuel sender and the retaining clips.
19. Remove the fuel sender assembly from the fuel tank.
20. Remove the EVAP pipe from the fuel tank roll over valves and the retaining clips.

Installation Procedure

1. Connect the EVAP pipe to the fuel tank roll over valves and the retaining clips.
2. Install the fuel sender assembly to the fuel tank.
3. Connect the fuel feed and return pipes to the fuel sender and the retaining clips.

Notice: Refer to Fastener Notice.

4. Install the fuel fill hose and the vent hose to the fuel tank.

Tighten the hose clamps to 2.5 N.m (22 lb in).




5. With the aid of an assistant, support and partially raise the fuel tank front end first.
6. Connect the fuel sender and the fuel pressure sensor electrical connectors.




7. Fully raise the fuel tank.
8. Install the fuel tank straps.
9. Install the fuel tank strap attaching bolts.

Tighten the bolts to 40 N.m (30 lb ft).




10. Connect the fuel fill hose and the vent hose to the pipes.

* Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in).
* Tighten the vent hose clamp to 2.5 N.m (22 lb in).

11. Install the fuel fill pipe to the fuel tank.
12. Remove the caps from the fuel and EVAP pipes.




13. Connect the EVAP vent pipe to the fuel canister.
14. Connect the chassis fuel pipes at the fuel filter.




15. Install the fuel tank protective shield.

Tighten fuel tank protective shield bolts to 25 N.m (18 lb ft).

16. Lower the vehicle.
17. Refill the fuel tank.
18. Install the fuel filler cap.
19. Connect the negative battery cable.
20. Use the following procedure in order to inspect for leaks:

1. Turn ON the ignition, with the engine OFF, for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

21. Install the engine sight shield.