Fuel Tank Removal/Installation Procedure

FUEL TANK REMOVAL/INSTALLATION PROCEDURE

REMOVAL-FRONT WHEEL DRIVE
1. Raise vehicle on hoist.
2. Drain fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove fuel filler cap before disconnecting any lines.

Fuel Tank Assembly:

4. Remove screws that hold filler tube to inner and outer quarter panel. The fuel pump module electrical connector has a retainer that locks it in place.






5. Raise vehicle. Slide fuel pump module electrical connector retainer to the unlock position.






6. Depress retaining tab on rear of electrical connector to allow connector latch to clear tab. Pull connector from pump module.
7. Disconnect fuel line quick connect fittings from the tank.
8. Use a transmission jack to support the fuel tank. Remove the bolts from the fuel tank straps.
9. Lower tank slightly. Carefully remove filler tube from tank.
10. Lower the fuel tank. Disconnect pressure relief/rollover valve hose. Remove clamp and remove fuel filler tube vent hose. Remove the fuel tank from the vehicle.

INSTALLATION-FRONT WHEEL DRIVE
1. Position fuel tank on transmission jack. Connect pressure relief/rollover valve hose. Connect fuel filler tube vent hose and replace clamp.
2. Raise tank into position and carefully work filler tube into tank. A light coating of transmission fluid on the tube end may be used to aid assembly.
3. Tighten strap bolts to 54 Nm 40 ft. lbs. torque. Remove transmission jack.

CAUTION: Ensure straps are not twisted or bent before or after tightening strap nuts.

4. Connect fuel pump/level unit electrical connector. Place retainer in locked position.
5. Lubricate the metal tubes on the fuel pump with clean 30 weight engine oil. Install the quick connect fuel fittings.
6. Attach filler tube to filler neck opening in quarter panel. Tighten quarter panel screws to 2 Nm 17 in. lbs. torque. On affected models be sure to install the gasket between the filler tube and the inner quarter panel, before installing the mounting screws.
7. Using a new clamp, install cap on fuel tank drain tube.
8. Fill fuel tank, replace cap, and connect battery ground cable.

CAUTION: When using the ASD Fuel System Test, the ASID relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Oft position.

9. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.