Fuel Tank: Service and Repair

REMOVAL

WARNING: Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible. Drain the fuel from the fuel tank before removing the tank.

1. Disconnect negative battery cable.
2. Remove rear seat cushion.
3. Disconnect fuel delivery module connector.




4. Remove three screws attaching access cover.




5. Remove rubber grommet and wires from access cover.

6. Remove access cover.
7. Remove two fuel hose quick connectors from fuel delivery module.
8. Raise vehicle.
9. Position a lifting device below center of fuel tank.
10. Disconnect two fuel hose quick connectors attached to fuel filter.
11. Disconnect fuel vapor hose attached to canister.
12. Loosen one joint hose clamp attached to fuel tank.
13. Disconnect joint hose from fuel tank.

14. Remove two bolts attaching fuel tank straps and remove fuel tank straps.

CAUTION: Cover the open ports on the fuel tank with plastic caps or other available covers to avoid fuel vapor contaminating the work area

15. Remove fuel tank from vehicle.

INSTALLATION

WARNING: Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible.

1. Raise vehicle.
2. Remove protective caps from fuel tank ports.




3. Place fuel tank on lifting device and carefully raise fuel tank assembly into correct position.

4. Reconnect joint hose to fuel tank and tighten clamp.




5. Reconnect two fuel hoses to fuel tank.

NOTE: Push evaporative hose onto fuel tank fitting at least 1.0 inch (25 mm). Push fuel filler hoses onto fuel tank and filler pipes at least 1.4 inches (35 mm).

6. Install fuel tank straps.

7. Install and tighten two bolts for fuel tank straps.

Tightening torque: 32 - 44 lb-ft (43 - 61 Nm, 4.4 - 6.2 kg-cm)

8. Install insulator and tighten bolts.
9. Lower vehicle.
10. Reconnect two fuel hoses to fuel delivery module.
11. Install rubber grommet and wires onto access cover.




12. Install access cover and tighten three screws.

Tightening torque: 7.7 - 12.2 lb-ft (10.8 - 16.7 Nm, 1.1 - 1.9 kg-m)




13. Reconnect two connectors to fuel delivery module.

14. Position wires correctly and secure to floor with tape.
15. Reinstall rear seat cushion.
16. Reconnect negative battery cable.