Fuel Tank Replacement

Fuel Tank Replacement

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


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) (Service and Repair)Fuel Pressure Relief (Without CH 48027) (Service and Repair).
3. Remove the exhaust system. Refer to Exhaust System Replacement (Service and Repair).
4. Remove the propeller shaft. Refer to Rear Propeller Shaft Replacement (All Wheel Drive) (Service and Repair)Rear Propeller Shaft Replacement (Rear Wheel Drive) (Service and Repair).




5. Disconnect the filler hose (1) from the fuel tank.
6. 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).




7. Disconnect the fuel feed hoses (4 and 5) from the fuel filter. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
8. Disconnect the fuel EVAP hose (6) from the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




9. Disconnect the fuel tank electrical connector.




10. Disconnect the EVAP hoses from the EVAP canister.
11. Pull outward on the retainer tab in order to disengage the retainer from the chassis.
12. Disconnect the electrical connector from the EVAP canister vent solenoid valve.
13. Disconnect the fuel tank pressure sensor electrical connector from the EVAP canister.




14. Remove the bolt (7) from the right side rear suspension bracket brace.
15. Loosen the nut (8) and allow the brace to swing downward. This will provide clearance while lowering the rear frame.




16. Remove the bolt (1) from the left side rear suspension bracket brace.
17. Loosen the nut (2) and allow the brace to swing downward. This will provide clearance while lowering the rear frame.




18. Raise the lower control arms using a suitable screw jack (3) in order to remove the load from the lower shock bolts (2).
19. Remove the lower shock bolts (2).
20. Remove the screw jack (3).




21. Position the screw jack under the rear frame near the adjuster tie bar, in order to support the front of the rear frame.
22. Remove the 2 front bolts from the rear frame.





Note: Use care not to over extend the rear brake hoses.

23. Lower the screw jack until there is approximately 50 mm (2 in) (a) between the front mounting surface of the rear frame and the chassis.
This will allow clearance to access the fuel tank strap bolts.




24. Remove the fuel tank strap bolts.
25. Position the fuel tank straps downward around the rear frame.
26. Carefully bend the fuel tank straps ONLY enough to allow the fuel tank to be removed.

Note: 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 canister
* The fuel/EVAP hoses at the chassis pipes

27. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
28. If replacing the fuel tank, remove the primary and secondary fuel tank modules. Refer to Primary Fuel Tank Module Replacement (Primary Fuel Tank Module Replacement) and Secondary Fuel Tank Module Replacement (Secondary Fuel Tank Module Replacement).

Installation Procedure

1. Install the primary and secondary fuel tank modules if previously removed. Refer to Primary Fuel Tank Module Replacement (Primary Fuel Tank Module Replacement) and Secondary Fuel Tank Module Replacement (Secondary Fuel Tank Module Replacement).

Note: 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 canister
* The fuel/EVAP hoses at the chassis pipes




2. With the aid of an assistant, carefully raise the fuel tank to the vehicle, aligning the filler neck with the filler hose.

Note: Ensure the fuel tank straps are not pressed into the fuel tank.

3. Carefully bend the fuel tank straps back to their original form.
4. Position the fuel tank straps around the rear frame and upward into position, aligning the holes in the straps with the threaded holes in the chassis.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the fuel tank strap bolts and tighten to 50 Nm (37 lb ft).




6. Connect the filler hose (1) to the fuel tank. Tighten the fuel filler tube hose clamp (3) to 3.5 Nm (31 lb in).
7. Connect the filler vent tube (2) to the EVAP hose. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




8. Connect the EVAP hoses to the EVAP canister.
9. Insert the retainer into the chassis and press inward on the tab to engage.
10. Connect the fuel tank pressure sensor electrical connector to the EVAP canister.
11. Connect the electrical connector to the EVAP canister vent solenoid valve.




12. Connect the fuel tank electrical connector.




13. Connect the fuel feed hoses (4 and 5) to the fuel filter. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
14. Connect the EVAP hose (6) to the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




15. Raise the rear frame using the screw jack.
16. Install the 2 front bolts to the rear frame and tighten to 265 Nm (195 lb ft).
17. Remove the screw jack.




18. Swing the left side rear suspension bracket brace into position and install the bolt (1) and tighten to 160 Nm (118 lb ft).

19. Tighten the rear suspension bracket brace nut to 85 Nm (63 lb ft).




20. Swing the right side rear suspension bracket brace into position and install the bolt (7) and tighten to 160 Nm (118 lb ft).
21. Tighten the rear suspension bracket brace nut (8) to 85 Nm (63 lb ft).




22. Position the screw jack (3) under the lower control arm in order to raise the lower control arms.
23. Install the lower shock bolts (2) and tighten to 150 Nm (111 lb ft).
24. Remove the screw jack (3).
25. Install the propeller shaft. Refer to Rear Propeller Shaft Replacement (All Wheel Drive) (Service and Repair)Rear Propeller Shaft Replacement (Rear Wheel Drive) (Service and Repair).
26. Install the exhaust system. Refer to Exhaust System Replacement (Service and Repair).
27. Install the engine sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair).
28. Refill the fuel tank.
29. Inspect for fuel leaks.