Removal and Replacement

Fuel Tank Replacement

Removal Procedure
Warning: Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedures.
3. Remove the exhaust system. Refer to Exhaust Muffler Replacement Service and Repair.
4. If required, remove the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.




5. Disconnect the evaporative emission line (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
6. Loosen the upper fill pipe clamp and hose clamp (2) and slide the hose up the filler pipe.




7. Disconnect the fuel tank electrical connector (1).
8. Disconnect the fuel line and evaporative emission line connectors (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures.




9. Disconnect the evaporative emission line (1) from the canister.




10. Support the fuel tank with a suitable jack.
11. Remove the fuel tank strap bolts (1) and reposition the straps (2) downward toward the front of the vehicle.
12. Using a suitable jack, lower the fuel tank (3).
13. Remove the following components if replacing just the fuel tank:

* The primary fuel tank module-Refer to Primary Fuel Tank Module Replacement (China) Primary Fuel Tank Module Replacement (China).
* The secondary fuel tank module-Refer to Secondary Fuel Tank Module Replacement Secondary Fuel Tank Module Replacement.

Installation Procedure

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

* The primary fuel tank module-Refer to Primary Fuel Tank Module Replacement (China) Primary Fuel Tank Module Replacement (China).
* The secondary fuel tank module-Refer to Secondary Fuel Tank Module Replacement Secondary Fuel Tank Module Replacement.




2. Raise the fuel tank (3) to the vehicle.

Caution: Refer to Fastener Caution Fastener Caution.

3. Ensure the fuel tank straps are seated properly. Install the fuel tank straps (2) and bolts (1) then tighten to 45 Nm(33 lb ft).




4. Connect the evaporative emission line (1) to the canister.




5. Connect the fuel tank electrical connector (1).
6. Connect the fuel line and evaporative emission line connectors (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures.




7. Connect the evaporative emission line (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
8. Install the filler tube and tighten the hose both clamp (2) to 5 Nm(44 lb in).
9. Perform a leak down test. Refer to Evaporative Emission System Diagnosis Evaporative Emission System Diagnosis.
10. If required, install the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.
11. Install the exhaust system. Refer to Exhaust Muffler Replacement Service and Repair.
12. Refill the fuel tank.
13. Inspect for fuel leaks.