Fuel Tank Assembly

Fuel Tank Replacement:

CAUTION:
- To help 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.
- Do not attempt to repair sections of nylon fuel pipes. If damaged, replace.
- If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.

REMOVE OR DISCONNECT
1. Disconnect negative battery cable.
2. Relieve fuel system pressure.
3. Drain fuel tank.
4. Raise vehicle on hoist.
5. Remove exhaust system.
6. Wheel house filler pipe opening cover to gain access to fuel tank filler neck.
7. Fuel filler neck attaching screws.
8. Fuel filler neck hose clamps and remove fuel filler neck.
9. Connectors at compressor.
10. Fuel feed, return, and vapor pipes near fuel filter.
11. Fuel vapor pipes and retainers at evaporative emission canister.
12. Rear tie rod ends.
13. Rear suspension support assembly bolts and Lower suspension support assembly.
14. Fuel tank straps (2).
15. Fuel tank.

DISASSEMBLE
If fuel tank in not being replaced proceed to "Install or Connect".

1. Harness retaining straps (2).
2. Fuel feed, return, and purge hoses.
3. Fuel sender assembly.

ASSEMBLE
1. Fuel sender assembly.
2. Fuel feed, return, and purge hoses.
3. Fuel filler hoses and clamps.

INSTALL OR CONNECT
1. Fuel tank with straps.

Tighten
Fuel tank strap bolts to 48 Nm (35 lb. ft.).

2. Rear suspension support assembly and bolts.

Tighten
Suspension support assembly bolts to 165 Nm (122 lb. ft.).

3. Rear tie rod ends.
4. Fuel vapor pipes and retainers at evaporative emission canister.
5. Fuel feed, return, and vapor pipes near fuel filter.
6. Connectors at compressor.
7. Fuel filler neck and hose clamps.
8. Wheel house filler pipe opening cover rear wheel house.
9. Exhaust system.
10. Lower vehicle.
11. Add fuel.
12. Fuel filler cap.
13. Negative battery cable.

INSPECT
Turn the ignition switch to "ON," position for two seconds, then turn to "OFF" for 10 seconds. Again turn to "ON" position, and check for fuel leaks.