Fuel Tank Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE

NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the rear compartment trim panel.
4. Remove the fuel sending unit access cover bolts.
5. Remove the access cover.




6. Disconnect the fuel sending unit electrical connector (3).
7. Disconnect the fuel tank pressure sensor electrical connector (5).
8. Remove the fuel fill pipe.
9. Remove the differential.




10. Disconnect the evaporative emission (EVAP) pipe quick connect fitting (1).
11. Disconnect the fuel feed pipe quick connect fitting (2).
12. Position a adjustable jack under the fuel tank.




13. Remove the fuel tank strap/support bolts (2).
14. Remove the fuel tank support bolts (3).
15. Remove the fuel tank supports (1).
16. Using the adjustable jack, lower the fuel tank until the EVAP canister vent solenoid electrical connector can be disconnected.




17. Completely lower the fuel tank.
18. Cap or plug the fuel feed and EVAP lines in order to prevent fuel loss and/or system contamination.




19. If the fuel tank is being replaced, perform the following:
- Disconnect and remove the fuel tank fill EVAP pipe (2).
- Disconnect and remove the fuel tank fuel feed pipe (4).
- Remove the EVAP canister.
- Remove the fuel pump module.

INSTALLATION PROCEDURE




1. If the fuel tank was replaced, perform the following:
- Install the fuel pump module.
- Install the EVAP canister.
- Install and connect the fuel tank fuel feed pipe (4).
- Install and connect the fuel tank fill EVAP pipe (2).




2. Remove the caps or plugs from the fuel feed and EVAP lines.
3. Partially raise the fuel tank.




4. Connect the EVAP canister vent solenoid electrical connector can be disconnected.
5. Position the fuel tank supports (1).

NOTE: Refer to Fastener Notice.

6. Install the fuel tank strap/support bolts (2).

Tighten the bolts to 22 N.m (16 lb ft).

7. Install the fuel tank support bolts (3).

Tighten the bolts to 22 N.m (16 lb ft).




8. Remove the adjustable jack from under the fuel tank.
9. Connect the fuel feed pipe quick connect fitting (2).
10. Connect the EVAP pipe quick connect fitting (1).
11. Install the differential.
12. Install the fuel fill pipe.
13. Lower the vehicle.




14. Connect the fuel tank pressure sensor electrical connector (5).
15. Connect the fuel sending unit electrical connector (3).




16. Install the fuel sending unit access cover.
17. Install the access cover bolts.

Tighten the bolts to 10 N.m (89 lb in).

18. Install the rear compartment trim panel.
19. Refill the fuel tank.
20. Connect the negative battery cable.
21. Inspect for leaks using the following procedure:
1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.