Removal and Replacement

REMOVAL PROCEDURE
1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.

IMPORTANT: Always maintain cleanliness when servicing fuel system components.

2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Vehicle Lifting.




4. Disconnect the fuel tank wiring harness connector at the body pass through (1).




5. Disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter (1).
6. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
7. Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
8. Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.




9. Remove the retaining nut for the EVAP canister bracket.




10. Loosen the fuel tank filler pipe hose clamp.
11. Disconnect the fuel tank filler pipe (2) from the fuel tank (1).




12. With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts (2).

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

13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
14. If the fuel tank is not being replaced, go to the Installation Procedure.




15. Disconnect the fuel tank wiring harness from the fuel sender assembly.
16. Remove the fuel sender shield from the fuel tank.
17. Disconnect the fuel feed and return pipe quick-connect fittings at the fuel sender (1).
18. Disconnect the EVAP vapor pipe assembly from the fuel sender.
19. Remove the fuel and/or EVAP pipe assembly from the fuel tank.
20. Remove the fuel sender assembly (1).
21. Remove the EVAP vent valve (2).
22. Remove the EVAP canister (3).

INSTALLATION PROCEDURE




1. Install the EVAP canister (3).
2. Install the EVAP vent valve (2).
3. Install the fuel sender assembly (1).
4. Install the fuel and/or EVAP pipe assembly.
5. Connect the EVAP vapor pipe to the fuel sender assembly.
6. Connect the fuel feed and fuel return pipes at the fuel sender.
7. Install the fuel sender shield to the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the shield nuts to 6 N.m (53 lb in).

8. Connect the fuel tank wiring harness to the fuel sender assembly.




9. With the aid of an assistant, position and support the fuel tank.




10. Install the fuel tank retaining strap attaching bolts (2).

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

Tighten
Tighten the fuel tank retaining strap bolts to 47 N.m (35 lb ft).




11. Install the EVAP canister retaining nut.

Tighten
Tighten the EVAP canister retaining nut to 6 N.m (53 lb in).




12. Connect the fuel tank filler pipe (2) to the fuel tank (1).

Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).




13. Connect the fuel feed pipe quick-connect fitting (1) at the inlet side of the fuel filter.
14. Connect the fuel return pipe quick-connect fitting near the fuel filter.
15. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.




16. Connect the fuel tank wiring harness connector (1) at the body pass-through.
17. Lower the vehicle.
18. Add fuel and reinstall the fuel tank filler pipe cap.
19. Connect the negative battery cable.
20. Inspect for fuel leaks with the following procedure:
20.1. Turn ON the ignition for 2 seconds.
20.2. Turn OFF the ignition for 10 seconds.
20.3. Turn ON the ignition.
20.4. Inspect for fuel leaks.