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Fuel Tank Replacement



Fuel Tank Replacement

Removal Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution (Gasoline/Gasoline Vapors Caution) .

1. Drain the fuel tank. Refer to Fuel Tank Draining (Service and Repair) .
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027 - LP1, LY7) (Fuel Pressure Relief (With CH 48027) (LY7) VIN 7 W/O Direct Fuel Injection)Fuel Pressure Relief (Without CH 48027 - LP1, LY7) (Fuel Pressure Relief (Without CH 48027) VIN 7 W/O Direct Fuel Injection)Fuel Pressure Relief (With High Pressure Pump - LLT) (Fuel Pressure Relief (With High Pressure Pump (LLT) VIN V W/ Direct Fuel Injection) .
3. Remove the exhaust system. Refer to Exhaust System Replacement (With LY7 and LLT) (Exhaust System Replacement (With LY7 and LLT))Exhaust System Replacement (With LP1) (Exhaust System Replacement (With LP1)) .
4. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (RWD) (Service and Repair)Rear Propeller Shaft Replacement (AWD) (Service and Repair) .





Important: Do not remove any components from the rear frame assembly once the rear frame assembly is removed from the vehicle.


5. Remove the rear frame assembly (2). Refer to Rear Frame Replacement (Service and Repair) .




6. Disconnect the filler hose (1) from the fuel tank.
7. Disconnect the filler vent tube (2) from the evaporative emission (EVAP) hose. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .




8. Disconnect the fuel feed pipe (1) from the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
9. Disconnect the fuel EVAP hose (2) from the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .




10. Release the electrical connector interlock and disconnect the fuel tank electrical connector.
11. Remove the fuel tank electrical connector retainer from the chassis.
12. Remove the fuel tank electrical harness from the chassis mounted retainer.




13. Disconnect the EVAP hoses from the EVAP canister.
14. Pull outward on the retainer tab in order to disengage the retainer from the chassis.




15. Disconnect the electrical connector from the fuel tank pressure sensor (1).
16. Disconnect the electrical connector from the EVAP canister vent valve.




17. Support the fuel tank with a suitable jack.
18. Remove the fuel tank strap bolts.
19. Remove the fuel tank straps.

Important: Ensure the following are free from the surrounding components while lowering the fuel tank:


* The fuel tank wiring harness

* The EVAP wiring harness

* The EVAP hoses at the EVAP

* The fuel/EVAP hoses at the chassis pipes



20. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
21. Remove the following components if replacing just the fuel tank:

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






Important: Ensure the following are properly routed while raising the fuel tank:


* The fuel tank wiring harness

* The EVAP wiring harness

* The EVAP hoses at the EVAP

* The fuel/EVAP hoses at the chassis pipes



2. With the aid of an assistant, carefully raise the fuel tank to the vehicle.
3. Install the fuel tank straps to the vehicle.

Notice: Refer to Fastener Notice (Fastener Notice) .

4. Install the fuel tank strap bolts.

Tighten the fuel tank strap bolts to 50 N.m (37 lb ft).





5. Connect the filler hose (1) to the fuel tank.

Tighten the fuel filler tube hose clamp (3) to 3.5 N.m (31 lb in).

6. Connect the filler vent tube (2) to the EVAP hose. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .




7. Connect the EVAP hoses to the EVAP canister.
8. Connect the EVAP purge valve and fuel tank pressure sensor electrical connectors.




9. Install the fuel tank wire harness and wire harness connector to the retainers on the chassis.
10. Connect the fuel tank electrical connector, and engage the connector interlock.




11. Connect the fuel EVAP hose (2) to the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
12. Connect the fuel feed pipe (1) to the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .




13. Install the rear frame assembly (2). Refer to Rear Frame Replacement (Service and Repair) .
14. Install the propeller shaft. Refer to Rear Propeller Shaft Replacement (RWD) (Service and Repair)Rear Propeller Shaft Replacement (AWD) (Service and Repair) .
15. Install the exhaust system. Refer to Exhaust System Replacement (With LY7 and LLT) (Exhaust System Replacement (With LY7 and LLT))Exhaust System Replacement (With LP1) (Exhaust System Replacement (With LP1)) .
16. Refill the fuel tank.
17. Inspect for fuel leaks.


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