Fuel Tank Assembly

REMOVAL PROCEDURE


Tools Required

- J34730, Fuel Pressure Gauge

- J 39765, Fuel Sender Lock Nut Wrench

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

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

3. Raise the vehicle.

4. Remove the exhaust system.

5. Remove the wheel house filler pipe (1) opening cover in order to gain access to the fuel tank filler pipe.

6. Remove the fuel tank filler pipe attaching screw (2).


7. Remove the fuel tank filler pipe (1) hose clamps and the fuel tank filler pipe.

8. Remove the fuel feed, fuel return, and vapor pipes near the fuel filter.

9. Remove the [1][2]EVAP pipes and retainers at the evaporative emission canister.

10. Remove the rear suspension support assembly.

11. Remove the fuel tank electrical connectors.

12. Remove the fuel tank bolts (3) from the fuel tank (2) straps.

13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.


DISASSEMBLE PROCEDURE

1. If the fuel tank is not being replaced, go to Installation Procedure.

2. Disassemble the harness retaining straps (2).

3. Disassemble the fuel feed, fuel return, and [1][2]EVAP hoses.

4. Disassemble the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.


ASSEMBLE PROCEDURE

1. Assemble the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.

2. Assemble the fuel feed, fuel return, and [1][2]EVAP hoses.

3. Assemble the harness retaining straps (2).

4. Assemble the fuel tank filler pipe and fuel tank filler pipe clamps.










INSTALLATION PROCEDURE

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

NOTICE: Do not repair sections of fuel pipes.

1. Position and support the fuel tank (4) with the aid of an assistant.

2. Install the fuel tank straps (2).

- Tighten the fuel tank strap bolts (3). Tighten the bolts to 48 N.m (35 lb. ft).

NOTICE: Refer to Fastener Notice in Service Precautions.

3. Install the rear suspension support assembly bolts and the lower suspension support assembly.

4. Install the fuel tank electrical connectors.

5. Install the [1][2]EVAP pipes and retainers at the evaporative emission canister.

6. Install the fuel feed, fuel return, and vapor pipes near the fuel filter.

7. Install the fuel tank filler pipe clamps and the fuel tank filler pipe.

- Tighten the fuel tank filler pipe clamps to 3 N.m (27 lb. in).

NOTICE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel tank filler pipe (1) attaching screw (2).

- Tighten the fuel tank filler pipe clamps to 8 N.m (71 lb. in).

NOTICE: Refer to Fastener Notice in Service Precautions.

9. Install the wheel house filler pipe opening cover.

10. Install the exhaust system.

11. Lower the vehicle.

12. Add fuel and install the fuel tank filler pipe (1) cap.

13. Install the negative battery cable.

14. Inspect for leaks.

14.1. Turn the ignition switch to the ON position for 2 seconds.

14.2. Turn the ignition switch to the OFF for 10 seconds.

14.3. Turn the ignition switch to the ON position.

14.4. Check for fuel leaks.