Fuel Tank Removal

TOOLS REQUIRED
^ J 34730 Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

NOTE: 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 system fuel pressure. Refer to Fuel Pressure Release.
2. Drain the fuel tank (1). Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

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




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




7. Remove the fuel teed (4) and fuel return (1) pipes.




8. Remove the [1][2]EVAP pipe (2) from the evaporative emission canister.




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

DISASSEMBLY PROCEDURE




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 [1][2]EVAP hoses.
4. Remove the fuel sender assembly.




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

ASSEMBLY PROCEDURE




1. Install the fuel tank filler pipe (1) to the fuel tank (3).
2. Install the fuel tank filler pipe assembly clamp (2) to the fuel tank filler pipe assembly (1).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the clamp to 3.5 Nm (31 lb in).




3. Install the fuel sender assembly.
4. Assemble the fuel feed, fuel return, and [1][2]EVAP hoses.
5. Assemble the fuel tank straps (2).