Fuel Tank Replacement

Fuel Tank Replacement

Removal Procedure

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


Warning: Refer to Gasoline/Gasoline Vapors Warning (Service Precautions).

Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).

1. Relieve the system fuel pressure. Refer to Fuel Pressure Relief (Service and Repair)
2. Drain the fuel tank. Refer to Fuel Tank Draining (Procedures).




3. Disconnect the evaporative emission and fuel pipes (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
4. Disconnect the fuel pressure sensor electrical connector (2).




5. Loosen the hose clamps (1) and remove the filler tube (2).




6. Disconnect the fuel tank harness electrical connector (1).




7. Support the fuel tank with a suitable jack.
8. Remove the fuel tank strap bolts (1).




9. Swing the fuel tank straps (1) out of the way.




10. Remove the fuel tank (1).
11. Remove the following components if replacing just the fuel tank.

1. Fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (NT7) (Fuel Tank Fuel Pump Module Replacement (NT7))Fuel Tank Fuel Pump Module Replacement (NU6) (Fuel Tank Fuel Pump Module Replacement (NU6)).
2. Evaporative emission carbon canister. Refer to Evaporative Emission Canister Replacement (Service and Repair).
3. Transfer components as necessary.

Installation Procedure

1. Install the following components if fuel tank replacement was necessary:

1. Fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (NT7) (Fuel Tank Fuel Pump Module Replacement (NT7))Fuel Tank Fuel Pump Module Replacement (NU6) (Fuel Tank Fuel Pump Module Replacement (NU6)).
2. Evaporative emission carbon canister. Refer to Evaporative Emission Canister Replacement (Service and Repair).




2. Use a suitable jack and install the fuel tank (1).




3. Reposition the fuel tank straps (1).





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the fuel tank strap bolts (1) and tighten to 20 Nm (15 lb ft).




5. Connect the fuel tank harness electrical connector (1).




6. Install the filler tube (2) and tighten the hose clamps (1) to 4Nm(35 lb in).
7. Connect the evaporative emission line (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service)




8. Connect the evaporative emission and fuel pipes (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Connect the fuel pressure sensor electrical connector (2).
10. Refill the fuel tank.
11. Inspect for fuel leaks.