Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Installation Procedure
- Install the fuel tank to the vehicle.
- Install the 2 fuel tank straps (1) to the vehicle with the four bolts (3).
Tighten: Tighten the bolts to 39 N.m (29 lb ft).
- Connect the 2 filler pipe vent lines (2) to the fuel tank.
- Connect the fuel filler hose (2) to the fuel tank.
- Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).
- Connect the fuel supply line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
- Install the EVAP canister to the vehicle. Refer to Evaporative Emission (EVAP) Canister Replacement (FWD) or Evaporative Emission (EVAP) Canister Replacement (AWD) .
- Secure the EVAP purge and vent lines (3) to the chassis with the body clip (1).
- Connect the EVAP lines (3) to the EVAP canister (2).
- Connect the EVAP drain hose (2) to the EVAP canister (1).
- Secure the parking brake cable (3) on the EVAP canister (2) side of the vehicle with 3 bolts (1).
Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
- Secure the parking brake cable (2) on the left side of the vehicle with 3 bolts (1).
Tighten: Tighten the bolts to 5.4 N.m (48 lb in).
- Install the rear exhaust heat shield (3) to the fuel tank (1).
- Secure the rear exhaust heat shield (3) with four rivets (2).
- Install the propeller shaft. Refer to Propeller Shaft Replacement - Two Piece in Propeller Shaft.
- Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle. Refer to Catalytic Converter Replacement (LV6 Engine) or Catalytic Converter Replacement (LNK Engine) in Engine Exhaust.
- Lower the vehicle.
- Install the fuel supply line (1) to the fuel sender fitting.
- Secure the fuel supply line (1) with the retaining clip (2).
- Connect the fuel sender electrical connector (2) to the fuel sender assembly.
- Connect the fuel tank pressure (FTP) sensor electrical connector (1) to the fuel sender assembly.
- Add fuel to the fuel tank.
- Connect the negative battery cable.
Tighten: Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
- Pressurize the fuel system and check for leaks.
- Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
- Install the access panel to the rear seat floor.
- Install the sill plate to the left side door opening.
- Install the rear seat bottom cushion. Refer to Seat Cushion Replacement - Rear in Seats.
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.