For 1990-2009 cars

### Removal Procedure

Caution: Provide additional support when a vehicle is on a hoist:

• | Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.

• | Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

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

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Raise the vehicle.
4. Remove the quick-connect fitting at the inlet side of the in-pipe fuel filter. Refer to Servicing Quick Connect Fittings .
5. Remove the Quick-Connect fitting on the fuel return pipe near the fuel filter.
6. Remove the fuel tank EVAP pipe quick-connect fitting at the EVAP pipe canister.
7. Remove the EVAP fuel filler pipe from the side of the fuel tank.
8. Remove the fuel tank filler pipe hose clamp.
9. Remove the fuel tank filler pipe.
10. Remove the fuel tank filler vent hose clamp.
11. Remove the fuel tank filler vent hose at filler neck.
12. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.
13. Remove the fuel sender electrical connector.
14. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
15. If the fuel tank is not being replaced, go to Install or Connect.
16. Remove the fuel feed and return pipe quick-connect fittings. Refer to Servicing Quick Connect Fittings .
17. Remove the fuel feed pipe.
18. Remove the fuel return pipe.
19. Remove the EVAP pipe assembly.
20. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

### Installation Procedure

1. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
2. Install the EVAP pipe assembly.
3. Install the fuel feed pipe.
4. Install the fuel return pipe.
5. Install the quick-connect fittings at the fuel sender. Refer to Servicing Quick Connect Fittings .
6. With the aid of an assistant, position and support the fuel tank.
7. Install the fuel sender electrical connector and the fuel sender retaining clips.
8. Install the fuel tank retaining strap attaching bolts.

Tighten
Tighten the fuel tank retaining strap bolts to 47.5 N·m (35 lb ft).

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.

9. Install the fuel tank filler vent hose to the fuel tank.

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

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.

10. Install the fuel tank filler pipe to the fuel tank.

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

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.

11. Install the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
12. Install the fuel return pipe quick-connect fitting near the fuel filter.
13. Install the EVAP fuel filler pipe to the side of the fuel tank.
14. Install the fuel tank EVAP pipe quick-connect fitting at the EVAP canister.
15. Lower the vehicle.
16. Add fuel and install the fuel tank filler pipe cap.
17. Install the negative battery cable.
18. Inspect for leaks:

18.1. | Turn the ignition switch to the ON position for 2 seconds.

18.2. | Turn the ignition switch to the OFF for 10 seconds.

18.3. | Turn the ignition switch to the ON position.

18.4. | Check for fuel leaks.