Removal and Installation

Item Description

1 Pressure Transducer
2 Fuel Tank
3 Fill Limiting Valve
4 Fuel Tank Filler Cap
5 Fuel Tank Filler Pipe
6 Fuel Tank Support Strap
7 Underbody
8 Pin (2 Req'd)
9 Nut (2 Req'd)
10 Fuel Tank Support
11 Stud (2 Req'd)
12 Fuel Filler Pipe Retainer
13 Screw
14 Screw (4 Req'd)
15 Screw (4 Req'd)
16 Fuel Filler Housing
17 Tee
18 Vapor Recirculating Hose Assy
19 GVV
A Tighten to 2.3-3.3 Nm (21-29 lb in)

WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN 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.

FUEL SUPPLY LINES ON ALL VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE TO PREVENT POSSIBLE INJURY. REFER TO FUEL PRESSURE RELEASE PROCEDURE.

REMOVAL

1. Relieve fuel system pressure.
2. Drain fuel from the fuel tank fuel tank prior to fuel tank removal.
3. Disconnect battery ground cable.
4. Remove four screws from the fuel filler housing to fuel tank filler pipe.
5. Raise vehicle on hoist.
6. Remove the four retaining screws from the fuel tank filler pipe.
7. Disconnect fuel supply and return lines at fuel pump.
8. Disconnect vapor line at tee on the RH side of fuel tank.
9. Disconnect the vapor line at crimp.
10. Remove the screw retaining the fuel tank filler pipe retainer to the fuel tank flange.
11. Remove the filler pipe. Refer to fuel tank filler pipe removal.
12. Disconnect electrical connector to the fuel pump module.
13. Place a safety support under the fuel tank. Remove the nuts from one end of the fuel tank support straps. The fuel tank support straps are hinged and will swing out of the way.
14. Remove fuel tank from the vehicle.
15. Remove and discard fuel tank mounting strap studs. Remove and discard old fuel tank filler pipe grommet.

INSTALLATION

1. Before proceeding, check the following:
a. Leak check the fuel pump module.
b. Verify evaporative emission valve and fuel tank mounted fuel vapor control valve are properly installed.
c. Make sure clips are installed properly on tank flange and vapor tubes are secured into clips.
d. Make all required connections which will be inaccessible after the fuel tank is installed.
2. Install new studs in existing J nuts prior to fuel tank installation. Install new fuel tank filler pipe grommet on fuel tank.
3. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel tank filler pipe with water base tire mounting lubricant. Install the fuel tank onto the fuel tank filler pipe then bring the fuel tank into final position.
4. Position the fuel tank support straps and start the retaining nut(s). Align fuel tank with the fuel tank support straps and check clearance to frame and underbody.
5. Check the hoses and wiring mounted on the fuel tank top to make sure they are correctly routed and will not be pinched between the fuel tank and body.
6. Tighten the fuel tank support strap retaining nuts to 30-40 Nm (23-29 lb-ft).
7. Rotate the fuel tank filler pipe into position with the fuel filler housing.
8. Install the four retaining screws for fuel tank filler pipe. Tighten to 2.3-3.3 Nm (21-29 lb in).
9. Fasten fuel tank filler pipe retainer, if removed. Tighten screws to 6.8-9.2 Nm (61-81 lb in).
10. Reconnect the fuel hoses and tubes.
11. Connect fuel pump module electrical connector.
12. Lower vehicle.
13. Install the four fuel filler housing retaining screws. Tighten to 2.3-3.3 Nm (21-29 lb in).
14. Replace fuel.
15. Connect battery ground cable.
16. Check for leaks.