Removal and Replacement

Fuel Tank Replacement

Special Tools

J-45722 - Fuel Sender Lock Ring Wrench

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Service and Repair).
2. Drain the fuel tank.
3. Remove the left rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement (Service and Repair).
4. Using compressed air, blow any dirt and/or debris from around the fuel fill pipe and evaporative emission (EVAP) line connections.
5. Loosen the fuel fill hose clamp (1) at the fill pipe.




6. Disconnect the fuel fill hose (2) from the fuel fill pipe.
7. Disconnect the fuel tank EVAP recirculation line quick connect fitting (1) from the fill pipe line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




8. Disconnect the left and right electronic position sensor links (1) from the ball studs.




9. Disconnect the fill pipe vent line (2) and the fuel tank vapor line (3) quick connect fittings from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




10. Disconnect the fuel feed line quick connect fitting (1) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




11. Disconnect the fuel tank wiring harness electrical connector (2) from the fuel tank pressure sensor.




12. Remove the fuel and EVAP line retainer (1) from the side rail.




13. Disconnect the body harness electrical connector from the fuel tank harness electrical connector (1).
14. Remove the fuel tank harness clips (2, 3) from the rear compartment side rail.
15. Remove the exhaust system. Refer to Exhaust System Replacement (Service and Repair).




16. Loosen the left and right rear brake hose bracket nut and slide the stud out of the keyhole slot in the side rail.




17. Remove the rear shock bolts.
18. Support the front of the vehicle with a jack stand at the engine cradle.
19. Support the rear suspension crossmember with a suitable adjustable jack.




20. Remove the rear suspension crossmember bolts.




21. Using the adjustable jack (1), slowly lower the rear suspension crossmember allowing the crossmember to pivot at the front bolts, until the rear springs can be removed.
22. Remove the rear coil springs.




23. Remove the fuel tank strap bolts.
24. Remove the fuel tank straps.
25. Remove the fuel tank.
26. Place the fuel tank on a suitable work surface.

Installation Procedure




1. Place the fuel tank onto the rear suspension crossmember.




2. Install the fuel tank straps.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the fuel tank strap bolts and tighten to 46 Nm (34 lb ft).
4. Install the rear coil springs while slowly raising the rear suspension crossmember using the adjustable jack (1).




5. Install the rear suspension crossmember bolts and tighten to 191 Nm (141 lb ft).
6. Remove the adjustable jack from the rear suspension crossmember.
7. Remove the jack stand from the front of the vehicle.




8. Install the rear shock bolts and tighten to 25 Nm (18 lb ft).




9. Connect the body harness electrical connector to the fuel tank harness electrical connector (1).
10. Install the fuel tank harness clips (2, 3) to the rear compartment side rail.




11. Install the fuel and EVAP line retainer (1) to the side rail.




12. Connect the fuel tank wiring harness electrical connector (2) to the fuel tank pressure sensor.




13. Connect the fuel feed line quick connect fitting (1) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




14. Connect the fill pipe vent line (2) and the fuel tank vapor line (3) quick connect fittings to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




15. Install the left and right rear brake hose bracket studs into the keyhole slots. Tighten the nuts to 10 Nm (89 lb in).
16. Install the exhaust system. Refer to Exhaust System Replacement (Service and Repair).




17. Connect the left and right electronic position sensor links (1) to the ball studs.





Note: Clean the fill pipe or any dirt or debris. Ensure the fill pipe is installed to the original depth to the fill hose. The fill pipe bead must be inserted into the hose past the clamp position.

18. Connect the fuel tank EVAP recirculation line quick connect fitting (1) to the fill pipe line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
19. Connect the fuel fill hose (2) to the fuel fill pipe.




20. Tighten the fuel fill hose clamp (1) at the fill pipe. Tighten the clamp to 4 Nm (35 lb in).
21. Install the left rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement (Service and Repair).
22. Fill the fuel tank.
23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).
24. Perform the following procedure in order to inspect for leaks:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.