Removal and Replacement

Fuel Tank Replacement

Removal Procedure

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


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

Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).

1. Relieve the system fuel pressure. Refer to Fuel Pressure Relief (Service and Repair).
2. Drain the fuel tank. Refer to Fuel Tank Draining (Procedures).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair)
4. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation (Service and Repair)
5. Remove the exhaust system for access. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement).
6. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
7. Remove the park brake cables. Refer to Parking Brake Rear Cable Replacement (Service and Repair).

* Support the rear suspension with a jack stand.
* Remove the front support bolts.
* Loosen the rear support bolts in order to slide the fuel tank out.
* For tightening specifications, refer to Rear Suspension Support Replacement (Service and Repair).




8. Disconnect the evaporative emission lines (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Disconnect the vent solenoid electrical connector (2).




10. Loosen the hose clamp (1) and remove the filler tube (2).
11. Disconnect the evaporative emission line (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




12. Disconnect the fuel tank electrical connector (1).
13. Disconnect the fuel feed line (3) and evaporative emission line (2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) and Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




14. Support the fuel tank with a suitable jack.
15. Remove the fuel tank strap bolts (1).
16. Remove the fuel tank.
17. Remove the following components if replacing just the fuel tank.

1. Fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement - Right Side (Fuel Tank Fuel Pump Module Replacement - Right Side).
2. Fuel level sensor. Refer to Fuel Level Sensor Replacement - Left Side (Fuel Level Sensor Replacement - Left Side).
3. Transfer components as necessary.

Installation Procedure

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

1. Fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement - Right Side (Fuel Tank Fuel Pump Module Replacement - Right Side).
2. Fuel level sensor. Refer to Fuel Level Sensor Replacement - Left Side (Fuel Level Sensor Replacement - Left Side).




2. Use a suitable jack and install the fuel tank.
Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the fuel tank strap bolts (1) and tighten to 50 Nm (37 lb ft).




4. Connect the fuel tank electrical connector (1).
5. Connect the fuel feed line (2) and evaporative emission line (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) and Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




6. Install the filler tube (2) and tighten the hose clamp (1) to 4 Nm (35 lb in) and remove the filler tube (2).
7. Connect the evaporative emission line (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




8. Connect the evaporative emission lines (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Connect the vent solenoid electrical connector (2).
10. Connect the parking brake cables at the calipers. Refer to Parking Brake Rear Cable Replacement (Service and Repair).
11. Install the rear suspension support and tighten to specifications. Refer to Rear Suspension Support Replacement (Service and Repair).
12. Install the park brake cables. Refer to Parking Brake Rear Cable Replacement (Service and Repair).
13. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
14. Install the exhaust system for access. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement).
15. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation (Service and Repair)
16. Refill the fuel tank.
17. Inspect for fuel leaks.