Fuel Tank Replacement (with E26)

Fuel Tank Replacement (with E26)

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
4. Disconnect the fuel fill pipe evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank EVAP line.
5. Loosen the fuel fill hose clamp (2) at the fuel tank and remove the hose from the tank.




6. Clean the fuel and EVAP pipe connections and the surrounding areas prior to disconnecting the lines in order to avoid possible contamination of the fuel and or EVAP system.
7. Disconnect the chassis fuel feed pipe quick connect fitting (2) from the fuel tank fuel feed pipe.
8. Disconnect the EVAP canister purge pipe quick connect fitting (1) from the chassis EVAP pipe.
9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid valve.




10. Support the fuel tank with an adjustable jack.
11. Remove the fuel tank strap bolts (1).
12. Remove the fuel tank straps (2).
13. With the aid of an assistant, carefully lower the fuel tank (3) until the fuel tank module connections can be accessed.
14. Disconnect the chassis wiring harness electrical connectors from the fuel tank pressure sensor and fuel tank module.
15. With the aid of the assistant, completely lower the fuel tank.
16. With the aid of the assistant, place the fuel tank in a suitable work area.
17. If replacing the fuel tank proceed to the next step, otherwise proceed to step 15 in the installation procedure.




18. Remove the fuel tank shield push on retainers (2).
19. Remove the fuel tank shield (1) from the fuel tank clips.




20. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module.
21. Remove the fuel feed pipe from the fuel tank clips (2 and 3).
22. Remove the fuel feed pipe (1) from under the EVAP front pipe.




23. Disconnect the EVAP front pipe quick connect fittings from the fuel tank module and roll over valve.
24. Remove the EVAP front pipe (1) from under the EVAP pipe.




25. Disconnect the EVAP pipe quick connect fitting from the fuel tank roll over valve.
26. Remove the adhesive tape securing the EVAP pipe to the fuel tank, if necessary.
27. Disconnect the EVAP pipe quick connect fitting from the fuel tank module.
28. Disconnect the EVAP pipe quick connect fitting from the EVAP canister.
29. Remove the EVAP pipe (1) from the fuel tank retainers (2, 3, and 4).
30. Remove the EVAP canister.
31. Remove the fuel tank module.

Installation Procedure




1. Install the fuel tank module.
2. Install the EVAP canister.
3. Install the EVAP pipe (1) to the fuel tank retainers (2, 3, and 4).
4. Connect the EVAP pipe quick connect fitting to the EVAP canister.
5. Connect the EVAP pipe quick connect fitting to the fuel tank module.
6. Connect the EVAP pipe quick connect fitting to the fuel tank roll over valve.
7. Secure the EVAP pipe to the fuel tank with adhesive tape, if necessary.




8. Install and route the EVAP front pipe (1) under the EVAP line.
9. Connect the EVAP front pipe quick connect fittings to the fuel tank module and roll over valve.




10. Install and route the fuel feed pipe (1) under the EVAP front pipe.
11. Connect the fuel feed pipe quick connect fitting to the fuel tank module.
12. Install the fuel feed pipe to the fuel tank clips (2 and 3).




13. Install the fuel tank shield onto the tank clips (1).
14. Install the fuel tank shield push on retainers (2).




15. With the aid of an assistant, place the fuel tank on the adjustable jack.
16. With the aid of the assistant, carefully raise the fuel tank (3) until the fuel tank module connections can be made.
17. Connect the chassis wiring harness electrical connectors to the fuel tank pressure sensor and fuel tank module.
18. With the aid of the assistant, completely raise the fuel tank.
19. Install the fuel tank straps (2).

Notice: Refer to Fastener Notice.

20. Install the fuel tank strap bolts (1).

Tighten the bolts to 25 N.m (18 lb ft).

21. Remove the adjustable jack from under the fuel tank.




22. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid valve.
23. Connect the EVAP canister purge pipe quick connect fitting (1) to the chassis EVAP pipe.
24. Connect the fuel feed pipe quick connect fitting (2) to the fuel tank fuel feed pipe.




25. Install the fuel tank fill hose to the fuel tank.
26. Connect the fuel fill pipe EVAP line quick connect fitting (1) to the fuel tank EVAP line.
27. Tighten the fuel fill hose clamp (2) at the fuel tank.

Tighten the clamp to 2.75 N.m (24 lb in).

28. Refill the fuel tank.
29. Install the fuel cap.
30. Connect the negative battery cable.
31. Perform the following procedure in order to inspect for leaks:

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