Fuel Tank Replacement - Left Side

Fuel Tank Replacement - Left Side

Tools Required

J 37088-A Fuel Line Disconnect Tool


Removal Procedure





1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)) .
3. Drain the fuel tank. Refer to Fuel Tank Draining (Service and Repair) .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
5. Remove the left rear tire. Refer to Tire and Wheel Removal and Installation (Service and Repair) .
6. Remove the left rear wheelhouse liner panel. Refer to Rear Wheelhouse Liner Panel Replacement (Service and Repair) .
7. Remove both mufflers. Refer to Exhaust Muffler Replacement - Left Side (Service and Repair) and Exhaust Muffler Replacement - Right Side (Service and Repair) .
8. Remove the driveline support assembly. Refer to Driveline Support Assembly Replacement (Driveline Support Assembly Replacement) .
9. Disconnect the fuel fill hose and the recirculation line from the fill pipe.
10. Disconnect the fuel pump jumper harness connector.




11. Disconnect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
12. Cap the fuel pipes to prevent fuel system contamination.




13. Loosen the fuel tank strap in order to drop the tank approximately one inch.




14. Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.





Important: The crossover tube CPA is released when the latch disengages from the tank connection groove.


15. Rotate crossover tube collar counterclockwise to disengage.




16. Disconnect the crossover tube from the left fuel tank by pulling straight out.

Important: Take care not to disturb the internal O-rings in the fuel tank connections.


17. Disconnect the evaporative emission (EVAP) crossover pipe (2) quick connect fitting at the left fuel tank.
18. Cap the EVAP pipe to prevent system contamination.




19. Remove the fuel tank strap mount bolts.
20. Remove the fuel tank strap from the vehicle.




21. Remove the fuel tank.



Installation Procedure





1. Install the fuel tank.
2. Install the fuel tank strap to the vehicle.




3. Install the fuel tank strap bolts loosely leaving the tank hanging approximately 1 inch.
4. Remove the cap from the EVAP pipe.




5. Connect the EVAP crossover pipe (2) quick connect fitting at the left fuel tank.




6. Lubricate the crossover tube to fuel tank connection O-rings (1-4) with P/N 1051717 rubber lubricant.





Important: Note the location of the T-shaped alignment feature (2) between the jet pump feed/return pipes connector.


7. Lubricate the crossover tube O-ring mating surfaces (1, 3 and 4) with P/N 1051717 rubber lubricant.
Important: Note the T-shaped alignment feature on the crossover tube.




Important: The crossover tube will not fully seat into the fuel tank if the jet pump lines are misaligned.


8. Connect the crossover tube to the left fuel tank using the features previously noted.

Important: The crossover tube collar tangs will not latch if misalignment exists.


9. Rotate the crossover tube collar (5) clockwise to engage the tangs.




10. Rotate the crossover tube CPA retainer counter-clockwise past the collar latching tang and push the tab (1) into the locked position.

Important: If the CPA retainer is locked into position, the crossover tube collar will not rotate.


11. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.





Notice: Refer to Fastener Notice (Fastener Notice) .

12. Tighten the fuel tank strap bolts.

Tighten the bolts to 25 N.m (18 lb in).

13. Remove the cap from the fuel pipes.




14. Connect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .




15. Connect the fuel pump jumper harness connector.
16. Connect the fuel fill hose and the recirculation line to the fill tube.

Tighten the clamp to 3.5 N.m (31 lb in).

17. Install the driveline support assembly. Refer to Driveline Support Assembly Replacement (Driveline Support Assembly Replacement) .
18. Install both mufflers. Refer to Exhaust Muffler Replacement - Left Side (Service and Repair) and Exhaust Muffler Replacement - Right Side (Service and Repair) .
19. Install the left rear wheelhouse liner panel. Refer to Rear Wheelhouse Liner Panel Replacement (Service and Repair) .
20. Install the left rear tire. Refer to Tire and Wheel Removal and Installation (Service and Repair) .
21. Lower the vehicle.
22. Refuel the fuel tank.
23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
24. Perform the following procedure in order to test for leaks:

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

25. Program the transmitters. Refer to Transmitter Programming (N. America and Japan, except Canada) (Programming and Relearning)Transmitter Programming (Canada and Europe) (Programming and Relearning) .