For 1990-2009 cars

## Fuel Tank Replacement FWD

### Removal Procedure

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Caution: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining .
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
4. Remove the muffler assembly. Refer to Muffler Replacement .
5. Disconnect the evaporative emission (EVAP) canister fresh air hose/pipe from the fuel tank fresh air hose/pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
6. Disconnect the EVAP canister vent hose/pipe from the EVAP canister (1). Refer to Plastic Collar Quick Connect Fitting Service .

Notice: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.

7. Disconnect the chassis fuel feed line quick connect fitting from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
8. Disconnect the fuel fill tube, EVAP vent hose, and fresh air hose from the fuel tank.
9. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.

Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

Important: Do not lower the rear frame. It is not necessary to lower the rear frame for fuel tank removal.

10. Support the fuel tank.
11. Remove the fuel tank strap bolts and fuel tank straps.
12. Lower the fuel tank from the underbody of the vehicle.
13. If replacing the fuel tank, remove the fuel tank module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .

### Installation Procedure

1. If previously removed, install the fuel tank module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .
2. Install the fuel tank heat shield and fuel tank assembly to the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the fuel tank straps and the fuel tank strap-to-body bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
6. Connect the fuel fill tube to the fuel tank.

Tighten
Tighten the clamp to 5 N·m (44 lb in).

7. Connect the chassis fuel feed line quick connect fitting to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
8. Connect the EVAP canister fresh air hose/pipe to the fuel tank fresh air hose/pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
9. Connect the EVAP canister vent hose/pipe to the EVAP canister (1). Refer to Plastic Collar Quick Connect Fitting Service .
10. Install the muffler assembly. Refer to Muffler Replacement .
11. Lower the vehicle .
12. Fill the fuel tank with gasoline.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
14. Tighten the fuel fill cap.
15. Prime the fuel system:

15.1. | Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.

15.2. | Repeat the previous step twice.

15.3. | Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.

15.4. | If the engine does not start, repeat steps 15.1-15.3.

16. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

## Fuel Tank Replacement AWD

### Removal Procedure

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Caution: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining .
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
4. Remove the muffler assembly. Refer to Muffler Replacement .
5. Remove the propeller shaft. Refer to Propeller Shaft Replacement .
6. Disconnect the evaporative emission (EVAP) canister fresh air hose/pipe from the fuel tank fresh air hose/pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
7. Disconnect the EVAP canister vent hose/pipe from the EVAP canister (1). Refer to Plastic Collar Quick Connect Fitting Service .

Notice: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.

8. Disconnect the chassis fuel feed line quick connect fitting from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
9. Disconnect the fuel fill tube, EVAP vent hose, and fresh air hose from the fuel tank.
10. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.

Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

11. Support the fuel tank.
12. Remove the fuel tank strap bolts and fuel tank straps.
13. Lower the fuel tank and heat shield from the underbody of the vehicle.
14. If replacing the fuel tank, remove the fuel tank module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .

### Installation Procedure

1. If previously removed, install the fuel tank module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .
2. Install the fuel tank heat shield and fuel tank assembly to the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the fuel tank straps and the fuel tank strap-to-body bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
6. Connect the fuel fill tube to the fuel tank.

Tighten
Tighten the clamp to 5 N·m (44 lb in).

7. Connect the chassis fuel feed line quick connect fitting to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
8. Connect the EVAP canister fresh air hose/pipe to the fuel tank fresh air hose/pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
9. Connect the EVAP canister vent hose/pipe to the EVAP canister (1). Refer to Plastic Collar Quick Connect Fitting Service .
10. Install the propeller shaft. Refer to Propeller Shaft Replacement .
11. Install the muffler assembly. Refer to Muffler Replacement .
12. Lower the vehicle .
13. Fill the fuel tank with gasoline.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
15. Tighten the fuel fill cap.
16. Prime the fuel system:

16.1. | Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.

16.2. | Repeat the previous step twice.

16.3. | Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.

16.4. | If the engine does not start, repeat steps 16.1-16.3.

17. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .