Removal and Replacement

Fuel Tank

Removal

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.

WARNING: After the fuel tank drain is complete always fit the sealing covers over the drain ports. Failure to do so will mean that fuel vapor can escape.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

CAUTION: Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

NOTE:
Removal steps in this procedure may contain installation details.
1
2 Disconnect the battery ground cable. For additional information, refer to Specifications Battery and Charging System
3
WARNING: Make sure to support the vehicle with axle stands.
Raise and support the vehicle.
4 For additional information, refer to Fuel System Pressure Release - 5.0L Service and Repair
5 For additional information, refer to Fuel Tank Draining




6




7 Remove the 4 nuts and remove the fuel tank RH access cover.
- TORQUE: 10 Nm
- Move the floor carpet aside.




8




9

10 For additional information, refer to Rear Driveshaft - 5.0L Rear Driveshaft





11 TORQUE: 5 Nm





12





13
NOTE:
Right-hand shown, left-hand similar.

- TORQUE: 22 Nm





14
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.






15





16
- TORQUE: 19 Nm





17





18
CAUTION: Position the breather hose and vent hose through the vehicle body during the fuel tank removal operation.
With assistance, remove the fuel tank.
- TORQUE: 19 Nm





19
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.






20
CAUTION: Be prepared to collect escaping fuel.
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.






21
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
TORQUE: 35 Nm





22
CAUTION: Take extra care not to damage the fuel tank level sensor float and arm.

- Depress the clips and release the lower part of the pump and sender unit rearward.
- Withdraw from the fuel tank.





23

Installation
1
CAUTION: Position the breather hose and vent hose through the vehicle body during the fuel tank installation operation.
To install, reverse the removal procedure.