Fuel Tank Replacement (Passenger/Cargo)
Fuel Tank Replacement (Passenger/Cargo)
Removal Procedure
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027)).
2. Drain the fuel tank. Refer to Fuel Tank Draining (with L59) (Service and Repair)Fuel Tank Draining (w/o L59) (Service and Repair).
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
4. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
5. Loosen the fuel fill hose clamp.
6. Disconnect the fuel fill hose (1) from the filler tube.
7. Disconnect the fuel fill vent hose (2) from the filler tube.
8. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Disconnect the rear fuel feed pipe at the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
10. With the aid of an assistant, support the fuel tank.
11. Remove and discard the attaching bolts (1) from the fuel tank strap.
12. Remove the fuel tank straps (2).
13. Carefully lower the fuel tank.
14. Disconnect the fuel tank module and the fuel pump electrical connectors.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel tank module (1) and the fuel pipes from the fuel tank. Refer to Fuel Tank Fuel Pump Module Replacement (Service and Repair).
18. Remove the evaporative emission (EVAP) hoses from the fuel tank.
19. On models with EVAP canister mounted to fuel tank, remove two tiedown straps from the (EVAP) canister (2) then remove the canister from the fuel tank. Discard tiedown straps.
20. On all models, remove the fuel fill hose from the fuel tank.
21. Remove the fuel tank from the fuel tank shield (3).
Installation Procedure
1. Install the fuel tank into the fuel tank shield (3).
Caution: Refer to Fastener Caution (Fastener Caution).
2. Install the fuel fill hose to the fuel tank and tighten the fuel fill hose clamp to 2.75 Nm (24 lb in).
3. On models with EVAP canister mounted to fuel tank, place the (EVAP) canister in position on the (EVAP) canister bracket, then install two new tiedown straps.
4. On all models, install the (EVAP) hoses to the fuel tank.
5. Install the fuel tank module (1) and the fuel pipes to the fuel tank. Refer to Fuel Tank Fuel Pump Module Replacement (Service and Repair).
6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the electrical connectors to the fuel tank module and fuel pump.
9. Raise the tank fully.
10. Install the fuel tank straps (2).
Note: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
11. Install the new attaching bolts (1) to the fuel tank strap and tighten the bolts to 20.5 Nm (15 lb ft).
12. Connect the chassis fuel feed pipe to the rear fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
13. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
14. Connect the fuel fill vent hose (2) to the filler tube.
15. Connect the fuel fill hose (1) to the fuel tank and tighten the fuel fill hose clamp to 2.75 Nm (24 lb in).
16. Lower the vehicle.
17. Refill the fuel tank.
18. Tighten the fuel filler cap.
19. Inspect for leaks:
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.