Service Procedure
The following procedure provides instructions for inspection, and if necessary, the replacement of the fuel tank.INSPECTION
1. Raise the vehicle on a suitable hoist and support as necessary.
2. Inspect the bottom side of the fuel tank to determine if the tank requires replacement.
^ If the fuel tank has the name "ABC GROUP" as shown above, then proceed to the next step and continue the inspection.
^ If the fuel tank does NOT have the name "ABC GROUP", then the fuel tank does NOT need to be replaced and no further action is required.
3. Lower the vehicle.
4. Open the hood.
5. Remove the cover from the underhood electrical center and remove the fuel pump relay.
6. Start the engine on the remaining fuel system pressure and allow it to run until stall.
7. Turn the ignition switch to the OFF position.
Caution
Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these instructions may result in personal injury.
Caution
Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.
8. Remove the fuel filler cap.
9. Use a hand or air operated pump device in order to drain as much fuel as possible through the filler neck. Remove the fuel.
10. Raise the vehicle.
11. Remove the bolt attaching the intermediate exhaust pipe bracket to the underbody.
12. Disconnect the rubber exhaust insulators (hangers) from the rear of the exhaust system and allow the system to rest on the rear axle.
13. Remove the four screws and one push-in retainer and remove the exhaust heat shield for the intermediate pipe.
14. Disconnect the electrical connector for the fuel tank sender.
15. Release the wiring harness from the retainer on the right fuel tank strap.
16. Loosen the clamp for the fuel fill hose and separate the hose from the fuel fill pipe. If necessary, the fuel fill hose connection to the fuel tank will be disconnected later in this procedure.
17. Disconnect the fuel feed quick-connect fitting from the fuel filter.
18. Disconnect the fuel return quick-connect fitting.
19. Disconnect the evaporative emission (EVAP) quick-connect fitting at the EVAP canister.
20. Support the fuel tank with a suitable jack.
21. Remove the bolts that attach the fuel tank straps to the underbody.
22. Unhook the other end of the fuel tank straps from the underbody.
23. With the aid of an assistant, lower and remove the fuel tank assembly.
24. Inspect the label as shown above, located on the top of the fuel tank.
^ If the bar code number on the label matches one of those listed at the end of this service procedure, then the fuel tank must be replaced. Proceed to the FUEL TANK REPLACEMENT procedure.
^ If the bar code number on the label does NOT match any of those shown, then the fuel tank does NOT need to be replaced. Proceed to Step 13 in the FUEL TANK REPLACEMENT procedure to reinstall the tank.
Fuel Tank Replacement
Tools Required
^ J-39765 Fuel Sender Lock Nut Wrench
Important
Before removing the fuel fill hose from the fuel tank, note the orientation of the hose so that it can be installed on the new fuel tank in the same position.
1. Loosen the clamp attaching the fuel fill hose and remove the hose from the fuel tank.
2. Disconnect the EVAP hose from the valve on the fuel tank.
3. Disconnect the electrical connectors from the fuel sender.
Important
^ The modular fuel sender may spring up.
^ When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float.
^ Carefully discard the reservoir fuel into an approved container.
4. Using J 39765, Fuel Sender Lock Nut Wrench, press down and rotate the retaining ring (1) to release the sender from the tank.
5. Carefully remove the fuel sender assembly (complete with all fuel lines) from the fuel tank and remove the fuel line strap from the fuel tank inlet.
6. Position the fuel line strap around the fuel inlet on the NEW fuel tank.
7. Using a new 0-ring seal, install the fuel sender in the fuel tank.
8. Slowly apply pressure to the top of the spring loaded sender until the sender aligns flush with the retainer on the tank.
Important
Be sure that the retaining ring is fully seated within the tab slots in the next step.
9. Using J 39765, rotate the retaining ring to engage and fully seat the ring within the tab slots.
10. Connect the electrical connectors to the fuel sender.
11. Connect the EVAP hose to the valve on the fuel tank.
12. Install the fuel fill hose and clamp on the fuel tank in the same orientation that was noted before removal from the old tank.
Tighten
Tighten to 3 Nm (27 lb in).
13. With the aid of an assistant, raise and position the fuel tank assembly to the vehicle.
14. Hook the fuel tank straps to the underbody.
15. Install the bolts in the fuel tank straps.
Tighten
Tighten bolts to 35 N.m (26 lb ft).
16. Connect the EVAP hose to the canister.
17. Connect the fuel feed and return line quick-connect fittings.
18. Install the fuel fill hose and clamp to the fill pipe.
Tighten
Tighten to 3 N.m (27 lb in).
19. Connect the wiring harness to the retainer on the fuel strap.
20. Connect the electrical connector to the fuel sender.
21. Position the exhaust shield to the underbody and install the screws and push-in fastener.
Tighten
Tighten the screws to 2 N.m (18 lb in).
22. Raise the exhaust system and connect the rubber insulators.
23. Position the intermediate exhaust bracket to the underbody and install the bolt.
Tighten
Tighten to 20 N.m (15 lb ft).
24. Lower the vehicle.
25. Fill the fuel tank and install the filler cap.
26. Install the fuel pump relay and install the cover on the electrical center.
27. Close the hood.
28. Inspect for leaks using the following procedure.
^ Turn the ignition switch to ON with the engine OFF for 2 seconds.
^ Turn the ignition switch to OFF for 10 seconds.
^ Turn the ignition switch to ON with the engine OFF.
^ Inspect for leaks.