Fuel Tank Replacement (VIN 4S558922 and Later (130MM Sender))

FUEL TANK REPLACEMENT (VIN 4S558922 AND LATER (130MM SENDER))

REMOVAL PROCEDURE

IMPORTANT: Always maintain cleanliness when servicing fuel system components.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
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 (1).




5. Disconnect the fuel pipes.




6. Remove the EVAP canister bracket nut.




7. Loosen the fuel tank fill pipe hose clamp.
8. Disconnect the fuel tank fill pipe (2) from the fuel tank (1).
9. Disconnect the EVAP vent pipe near the fill pipe hose.




10. With the aid of an assistant or a transmission jack, support the fuel tank and remove the fuel tank strap attaching bolts (2).
11. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.




12. If the fuel tank is being replaced, perform the following steps:
12.1. Remove the fuel sender (1).
12.2. Remove the fuel tank wiring harness from the fuel tank.
12.3. Remove the fuel pipes from the fuel tank.
12.4. Remove the EVAP vent solenoid valve (2).
12.5. Remove the EVAP canister (3).

INSTALLATION PROCEDURE




1. Install the EVAP canister (3).
2. Install the EVAP vent solenoid valve (2).
3. Install the fuel pipes to the fuel tank.
4. Install the fuel tank wiring harness to the fuel tank.
5. Install the fuel sender (1).




6. With the aid of an assistant or a transmission jack, position and support the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.




7. Install the fuel tank strap bolts (2).

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




8. Install the EVAP canister bracket nut.

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

9. Install the EVAP vent pipe near the fill pipe hose.




10. Install the fuel tank filler pipe hose (2) to the fuel tank (1).

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




11. Connect the fuel pipes.




12. Install the fuel tank wiring harness connector (1).
13. Lower the vehicle.
14. Add fuel as necessary and install the fuel tank filler pipe cap.
15. Inspect for fuel leaks. Perform the following steps:
15.1. Turn ON the ignition for 2 seconds.
15.2. Turn OFF the ignition for 10 seconds.
15.3. Turn ON the ignition.
15.4. Inspect for fuel leaks.