Fuel Tank Replacement

Fuel Tank Replacement

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

Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.




1. 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)).
2. Drain the fuel tank. Refer to Fuel Tank Draining (Service and Repair).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
4. Disconnect the fuel tank vent pipe quick connect fittings (1, 4). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Loosen the fuel fill pipe hose clamp (2) at the fuel tank.
6. Remove the fuel fill pipe hose from the fuel tank.




7. Disconnect the fuel tank electrical connector (1) from the pass through connector.




8. Remove the exhaust pipe insulators from the underbody hangers.
9. Remove the muffler insulators from the underbody hanger and slowly lower the exhaust in order to allow it to rest on the rear axle beam.




10. Place an adjustable jack under the fuel tank.
11. Remove the fuel tank strap bolts.
12. Remove the fuel tank straps.
13. Using the adjustable jack, carefully lower the fuel tank away from the vehicle.
14. With the aid of an assistant, place the fuel tank on a suitable work surface.




15. If replacing the fuel tank, perform the following steps. Remove the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




16. Remove the fuel feed intermediate pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




17. Remove the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




18. Disconnect and remove the fuel tank electrical harness.
19. Remove the fuel tank module. Refer to Fuel Pump Module Replacement (Service and Repair).

Installation Procedure




1. If the fuel tank was replaced, perform the following steps. Install the fuel tank module. Refer to Fuel Pump Module Replacement (Service and Repair).
2. Install and connect the fuel tank electrical harness.




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




4. Install the fuel feed intermediate pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




5. Install the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




6. With the aid of an assistant, place the fuel tank on the suitable jack.
7. Using the adjustable jack, carefully raise the fuel tank into position.
8. Position the fuel tank straps.

Caution: Refer to Fastener Caution (Fastener Caution).

9. Install the fuel tank strap bolts.

Tighten the bolts to 45 Nm (33 lb ft).

10. Remove adjustable jack from under the fuel tank.




11. Raise the exhaust and install the muffler insulators to the underbody hangers.
12. Install the exhaust pipe insulators to the underbody hangers.




13. Connect the fuel tank electrical connector (1) to the pass through connector.




14. Install the fuel fill pipe hose to the fuel tank.
15. Tighten the fuel fill pipe hose clamp (2) at the fuel tank.

Tighten the clamp to 4.5 Nm (40 lb in).

16. Connect the fuel tank vent pipe quick connect fittings (1, 4). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
17. Lower the vehicle.
18. Refill the fuel tank.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
20. Inspect for fuel leaks using the following procedure:

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