Fuel Tank Removal and Installation

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE

CAUTION: Provide additional support when a vehicle is on a hoist in the following ways:
- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

NOTE: The fuel tank equipped with ORVR components require special handling. Follow all instructions for servicing the fuel tank as specified in the service procedures. Damage to the fuel system components and the failure to meet the Federal Regulations may result from incorrect servicing of the fuel tank.




1. Drain the fuel tank. Refer to Fuel Tank Draining. Service and Repair
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
3. Remove the catalytic converter and intermediate pipe assembly from the vehicle.
4. Remove the 2 left side bolts (1) and the 3 right side bolts (3) from the rear exhaust heat shield (2).
5. Remove the rear exhaust heat shield (2) from the underbody.




6. Remove the 2 bolts (1) securing the parking brake cable (2) on the right side of the vehicle.




7. Disconnect the fuel supply line.
8. Disconnect the fuel tank vapor line with the quick release fitting from the fuel vapor pipe.




9. Loosen the fuel filler hose clamp (1).
10. Disconnect the fuel filler hose (2) from the fuel tank.
11. Disconnect the ORVR vent line from the fill limiter vent valve (FLVV) of the evaporative emission (EVAP) canister.




12. Remove the 4 bolts (1) and the 2 fuel tank straps (2) from the vehicle.
13. Remove the fuel tank (3) from the vehicle.If replacing the fuel tank, remove all lines and hoses, and install on the replacement fuel tank.

INSTALLATION PROCEDURE




1. Install the fuel tank (3) to the vehicle.

2. NOTE: Refer to Fastener Notice.

Install the 2 fuel tank straps (2) to the vehicle with the 4 bolts (1).

Tighten the bolts to 39 N.m (29 lb ft).




3. Connect the fuel filler hose (2) to the fuel tank.
4. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).




5. Connect the fuel supply line.
6. Connect the fuel tank vapor line with the quick release fitting to the fuel vapor pipe.
7. Connect the ORVR vent line to the FLVV on the EVAP canister.




8. Secure the parking brake cable (2) on the right side of the vehicle with 2 bolts (1).

Tighten the bolts to 5.4 N.m (48 lb in).




9. Install the rear exhaust heat shield (2) to the vehicle underbody.
10. Secure the rear exhaust heat shield (2) with the 2 left side bolts (1) and the 3 right side bolts (3).

Tighten the bolts to 5.4 N.m (48 lb in).
11. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle.
12. Lower the vehicle.
13. If the fuel sender assembly was removed refer to Fuel Sender Assembly Replacement.




14. Connect the ORVR vent line (2) to the fuel sender assembly (1).




15. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).




16. Connect the fuel supply line (1) to the fuel sender assembly.




17. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).




18. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
19. Add fuel to the fuel tank.
20. Connect the negative battery cable.

Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
21. Pressurize the fuel system and check for leaks.
22. Install the access panel (1) to the rear seat floor panel (3).
23. Secure the access panel to the body with 4 bolts.

Tighten the 4 bolts to 6 N.m (53 lb in).
24. Relocate the carpet under the ride side seat area and the right sill plate area.
25. Install the sill plate to the right side door opening.




26. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2).

Tighten the 2 bolts to 41 N.m (30 lb ft).