Tools Required

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

Important: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace the pipes.

1. Relieve the fuel pressure. Refer to the Fuel Pressure Relief .



2. Drain the fuel tank (1). Refer to Fuel Tank Draining .

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

3. Raise the vehicle.
4. Remove the exhaust system.



5. Remove the filler pipe opening cover (2) in the wheel house .
6. Remove the fuel filler pipe attaching bolt (4) from the ground wire strap (3).



7. Remove the fuel feed (4) and fuel return (1) pipes. Refer to Plastic Collar Quick Connect Fitting Service .



8. Remove the EVAP pipe (2) from the evaporative emission canister.



9. Remove the rear suspension support assembly. Refer to Support Replacement in Rear Suspension.
10. Remove the fuel tank electrical connector (1).
11. Remove the bolts (4) from the fuel tank straps (2).
12. Remove the fuel tank (5) from the vehicle and place the fuel tank in a suitable work area.

1. If the fuel tank is not being replaced, go to the Installation Procedure.
2. Disassemble the fuel tank straps (2).
3. Disassemble the fuel feed, the fuel return, and the EVAP hoses.
4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .



5. Remove the clamp (2) from the fuel filler pipe assembly (1).
6. Remove the fuel filler pipe assembly (1) from the fuel tank (3).

1. Install the fuel filler pipe (1) to the fuel tank (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the clamp (2) to the fuel filler pipe assembly (1).

Tighten
Tighten the clamp to 3.5 N·m (31 lb in).




3. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
4. Assemble the fuel feed, the fuel return, and the EVAP hoses.
5. Assemble the fuel tank straps (2).

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.
1. Position and support the fuel tank (4) with the aid of an assistant.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the fuel tank straps (2).

Tighten
Tighten the bolts to 42 N·m (31 lb ft).

3. Install the rear suspension support assembly bolts and the lower suspension support assembly. Refer to Support Replacement in Rear Suspension.
4. Install the fuel tank electrical connector (1).



5. Install the EVAP pipe (2) to the evaporative emission canister.



6. Install the fuel feed (4) and fuel return (1) pipes. Refer to Plastic Collar Quick Connect Fitting Service .



7. Install the filler pipe attaching bolt (4) to the ground wire strap (3).

Tighten
Tighten the fuel tank filler pipe attaching bolt to 9 N·m (80 lb in).

8. Install the exhaust system.
9. Lower the vehicle.
10. Add fuel to the fuel tank.
11. Install the fuel filler pipe cap.
12. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
13. Inspect for leaks.

13.1.

Turn ON the ignition switch for 2 seconds.

13.2.

Turn OFF the ignition switch for 10 seconds.

13.3.

Turn ON the ignition switch.

13.4.

Check for fuel leaks.