Fuel Tank Replacement

Fuel Tank Replacement (AWD)

Removal Procedure

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


Warning: Refer to Safety Glasses Warning Safety Glasses Warning.


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 propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.

4. Remove the exhaust system. Refer to Exhaust Muffler Replacement (FWD) Service and RepairExhaust Muffler Replacement (AWD) Service and Repair.

5. Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement Service and Repair.




6. Disconnect the fuel tank fuel pump module wiring harness (2).

7. Unclip the fuel tank module wiring harness from the chassis (1).





Warning

Do not breathe the air through the EVAP component tubes or hoses. The fuel vapors inside the EVAP components may cause personal injury.

8. Disconnect the fuel tank filler vent pipe from the fuel tank filler vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

9. Disconnect the fuel tank filler tube (2) from the fuel tank.




10. Disconnect the evaporative emission purge and fuel feed pipes (1). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

11. Disconnect the fuel pressure sensor harness connector (2).

12. Disconnect the wiring harness connector from the fuel pipe.

13. Position a suitable hydraulic lift below the fuel tank.




14. Remove both fuel tank strap fasteners (3).

15. Remove both fuel tank straps (2) from the fuel tank (1).

Warning

To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack.

Caution:
When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.

Note: carefully maneuver the fuel tank past the exhaust system.

16. With the aid of an assistant, lower the hydraulic lift to remove the fuel tank from the vehicle.

17. Remove the fuel tank from the hydraulic lift.

Installation Procedure

1. If replacing the fuel tank transfer the following components.




* The evaporative emission canister (2). Refer to Evaporative Emission Canister Replacement (AWD) Service and RepairEvaporative Emission Canister Replacement (FWD) Service and Repair.




* The evaporative emission canister purge pipe (1). Refer to Evaporative Emission Canister Purge Pipe Replacement (AWD) Evaporative Emission Canister Purge Pipe ReplacementEvaporative Emission Canister Purge Pipe Replacement (FWD) Evaporative Emission Canister Purge Pipe Replacement.




* The fuel tank feed pipe (2). Refer to Fuel Feed Pipe Replacement (At Engine) Fuel Feed Pipe Replacement (At Engine)Fuel Feed Pipe Replacement (At Tank FWD) Fuel Feed Pipe Replacement (At Tank)Fuel Feed Pipe Replacement (At Tank AWD) Fuel Feed Pipe Replacement (At Tank).




* The sender assembly (1). Refer to Fuel Sender Assembly Replacement (AWD) Service and Repair.




* The tank fuel pump module (1). Refer to Fuel Tank Fuel Pump Module Replacement (AWD) Fuel Tank Fuel Pump Module ReplacementFuel Tank Fuel Pump Module Replacement (FWD) Fuel Tank Fuel Pump Module Replacement.

* The fuel tank wiring harness.





Note: carefully maneuver the fuel tank past the exhaust system.

2. With the aid of an assistant, position the fuel tank on a hydraulic lift and raise into vehicle position.

Caution: Refer to Fastener Caution Fastener Caution.

3. Install both fuel tank straps (2) to the fuel tank (1) and tighten the fasteners (3) to 27 Nm (20 lb ft).

4. Remove the hydraulic lift from the fuel tank.




5. Connect the evaporative emission purge and fuel pipes (1). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

6. Connect the fuel pressure sensor harness connector (2).




7. Install the fuel tank filler tube (2) and tighten the clamp (1).

8. Connect the fuel tank filler vent pipe to the fuel tank filler vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.




9. Connect the fuel tank fuel pump module wiring harness (2).

10. Clip the fuel tank module wiring harness to the chassis (1).

11. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement Service and Repair.

12. Install the exhaust system. Refer to Exhaust Muffler Replacement (FWD) Service and RepairExhaust Muffler Replacement (AWD) Service and Repair.

13. Install the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.

14. Refuel the fuel tank.