Fuel Tank Replacement (Rear Tank)

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Remove the spare tire stowage lock cylinder.




3. Remove the spare tire from the hoist.
4. Remove the rear exhaust hanger bolts and hanger.




5. Remove the spare tire hoist crossmember and bolts.
6. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Front Tank)Fuel Tank Draining Procedure (Rear Tank).




7. Loosen the fuel tank fill hose clamp at the front tank.
8. Separate the fill hose from the front tank.




9. Remove the fuel pipe ground strap bolt.
10. Separate the ground straps (1, 2).




11. Loosen the fuel tank vent hose clamp at the rear tank.
12. Separate the vent hose from the rear tank.




13. Loosen the fuel tank fill pipe clamp at the rear tank.
14. Separate the fill pipe from the rear tank.
15. Loosen the vent hose clamp at the rear tank.
16. Separate the vent hose from the rear tank.
17. Lower the vehicle.




18. Remove the fuel tank filler housing to body screws (1), and retainer (2).




19. Remove the fuel tank filler housing to fuel tank fill pipe screws.
20. Remove the fuel tank filler housing from the vehicle.
21. Remove the fuel fill pipe from the vehicle.
22. Raise the vehicle.
23. Support the fuel tank with a suitable jack.




24. Remove the fuel tank strap bolts.

NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

25. Remove the fuel tank straps.
26. With the aid of an assistant, partially lower the rear tank.




27. Open the retaining clip.
28. Remove the hose from the retaining clip.
29. Remove the evaporative emission (EVAP) and fuel pipes from the retaining clip.




30. Loosen the fuel tank fill hose clamp at the rear tank.
31. Remove the fuel tank fill hose from the rear tank.




32. Disconnect the EVAP tubes (2) at the EVAP pipes.
33. Disconnect the fuel pipe at the fuel sending unit (1).
34. Cap the EVAP and fuel pipes in order to prevent possible fuel/EVAP system contamination.




35. Disconnect the fuel tank electrical connector.
36. Completely lower the fuel tank.
37. With the aid of an assistant, remove the tank from the jack.
38. If necessary, remove the sending unit.
39. Remove the EVAP pipes from the fuel tank rollover valve and retaining clips, if required.

INSTALLATION PROCEDURE




1. Install the EVAP pipes to the fuel tank rollover valves and retaining clips, if required.
2. If necessary, install the sending unit.
3. With the aid of an assistant, install the tank to the jack.
4. Partially raise the fuel tank.
5. Connect the fuel tank electrical connector.




6. Remove the caps from the EVAP and fuel pipes.
7. Connect the fuel pipe at the fuel sending unit (1).
8. Connect the EVAP tubes (2) at the EVAP pipes.




9. Install the fuel tank fill hose to the rear tank.
10. Position the hose clamp downwards, for easy access.

NOTE: Refer to Fastener Notice in Service Precautions.

11. Tighten the fuel tank fill hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in).




12. Install the EVAP and fuel pipes to the retaining clip.
13. Install the hose to the retaining clip.
14. Close the retaining clip.
15. With the aid of an assistant, fully raise the rear tank.




16. Install the fuel tank straps.
17. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N.m (30 lb ft).

18. Remove the jack from the fuel tank.
19. Lower the vehicle.




20. Install the fuel fill pipe to the vehicle.
21. Install the fuel tank filler housing to the vehicle.
22. Install the fuel tank filler housing to fuel tank fill pipe screws.

Tighten
Tighten the screws to 2.3 N.m (20 lb in).




23. Install the fuel tank filler housing to body screws (1), and retainer (2).

Tighten
Tighten the screws to 2.3 N.m (20 lb in).

24. Raise the vehicle.




25. Install the vent hose to the rear tank.
26. Tighten the vent hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in).

27. Install the fill pipe to the rear tank.
28. Tighten the fuel tank fill pipe hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in).




29. Install the vent hose to the rear tank.
30. Tighten the vent hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in).




31. Position the ground straps (1, 2).
32. Install the fuel pipe ground strap bolt.

Tighten
Tighten the bolt to 9 N.m (80 lb in).




33. Install the fill hose to the front tank.
34. Tighten the fill hose clamp at the front tank.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in).




35. Install the spare tire hoist crossmember and bolts.

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

36. Install the rear exhaust hanger and bolts.

Tighten
Tighten the bolts to 30 N.m (22 lb ft).

37. Lower the vehicle.




38. Install the spare tire to the hoist.




39. Install the spare tire stowage lock cylinder.
40. Refill the fuel tank.
41. Install the fuel fill cap.
42. Connect the negative battery cable.
43. Using the following procedure in order to inspect for leaks:
43.1. Turn the ignition OFF, with the engine OFF, for 2 seconds.
43.2. Turn the ignition ON for 10 seconds.
43.3. Turn the ignition OFF, with the engine OFF.
43.4. Inspect for fuel leaks.