Fuel Tank: Service and Repair

FUEL TANK












Exploded View

Special Tool(s):

Special Tool(s)

Removal

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, and possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.
- The fuel in the tank may be pressurized. Remove the fuel tank cap slowly. If a hissing sound is heard, wait until the condition stops before removing the fuel tank filler cap. If these precautions are not followed, fuel may spray and cause personal injury.

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Disconnect the battery ground cable.

4x4 vehicles
4. Support the exhaust system with a suitable stand, release the 3 rear exhaust hangers and carefully lower the exhaust system to allow enough clearance to remove the fuel tank.
5. Remove the rear driveshaft.

All vehicles
6. Lift the LH rear seat cushion and position the carpet aside.
7. Remove the 4 screws and the fuel pump module access cover.
8. Disconnect the fuel pump module electrical connector.
9. Disconnect the fuel vapor control tube assembly valve electrical connector.







10. Disconnect the fuel supply tube quick connect coupling.
1 Press the fuel supply tube quick connect coupling lock tabs.
2 Disconnect the fuel supply tube quick connect coupling.







11. Using a suitable fuel pump lock ring remover, rotate the lock ring counterclockwise and remove.

CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and filter.







12. Prior to completely removing the fuel pump, position it aside and using the special tool and a suitable fuel recovery system, drain the fuel tank.







13. CAUTION: Some fuel will remain in the fuel pump module after draining the fuel tank. Carefully drain the fuel pump module into a suitable container.

To release the bottom-mounted fuel pump module, reach into the fuel pump module opening and squeeze the retainer tabs on the pump module housing and pull upward.

14. NOTE: Be careful that no foreign material falls into tank.

Remove and discard the fuel pump module O-ring seal, making sure the mounting area is clean and free of foreign material.

15. Reposition the clamp and disconnect the fuel filler pipe hose from the fuel tank.







16. Position a suitable lifting device under the fuel tank.
17. Detach the wiring harness pin-type retainers from the fuel tank strap.
18. Remove the bolt and the LH fuel tank strap.
19. Remove the bolt and the RH fuel tank strap.
20. Partially lower the fuel tank enough to access and release the fuel vapor control tube assembly valve quick connect.
- Remove the fuel tank.

Installation

All vehicles

1. CAUTION:
- Inspect the surfaces of the fuel pump module flange and fuel tank O-ring contact surfaces. Do not polish or adjust the O-ring contact area of the fuel pump flange or fuel tank. Install a new fuel pump module or fuel tank if the O-ring contact area is bent, scratched or corroded.
- Make sure to install a new fuel pump module O-ring and lock ring.

NOTE: Lubricate the fuel pump module O-ring seal with clean engine oil.

Install a new fuel pump module O-ring seal.







2. NOTE: When installing the fuel pump module, make sure to align the locator tabs on the fuel tank mounting flange.

Install the fuel pump module.

3. NOTE: Be sure the aligning tabs of the fuel pump module unit are positioned in the slot before tightening the lock ring.

Holding the fuel pump module O-ring seal in place, rotate the lock ring clockwise until it stops against the retainer tabs.

4. Position the fuel tank on a suitable lift and raise the tank enough to connect the fuel vapor control tube valve assembly quick connect.
- Raise the tank into the installed position.

5. Install the RH fuel tank strap and bolt.
- Tighten to 55 Nm (41 lb-ft).

6. Install the LH fuel tank strap and bolt.
- Tighten to 55 Nm (41 lb-ft).

7. Attach the wiring harness pin-type retainers to the fuel tank strap.
8. Install the fuel filler pipe hose and clamp on the fuel tank.
- Tighten to 4 Nm (36 lb-in).







9. NOTE: Make sure the collar on the fuel tube is inserted fully into the quick connect coupling before the locking tang is locked.

Connect the fuel supply tube quick connect coupling.
1 Connect the fuel supply quick connect coupling to the fuel pump module.
2 Press the fuel supply quick connect coupling locking tang into position.
- Pull on the fitting to make sure it is fully engaged.

10. Connect the fuel pump module electrical connector.
11. Connect the fuel vapor control tube assembly valve electrical connector.
12. Install the fuel pump module access cover and screws.
13. Reposition the carpet and install the LH rear seat cushion.

4x4 vehicles
14. Install the rear driveshaft.
15. Position the exhaust system and install the rear hangers.

All vehicles
16. Turn the ignition key to the ON position to pressurize the fuel system.
17. Visually inspect the fuel system for leaks.