Removal and Replacement

Fuel Tank Replacement

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027)).
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
3. Remove the frame brace. Refer to Frame Brace Replacement (Service and Repair).
4. Remove the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (Service and Repair).
5. Drain the fuel tank. Refer to Fuel Tank Draining (Procedures).




6. Disconnect the evaporative emission (EVAP) canister fresh air pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
7. Disconnect the EVAP canister solenoid pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
8. Disconnect the EVAP purge pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




9. Disconnect the fuel filler pipe recirculation hose from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
10. Loosen the clamp securing the fuel fill pipe to the fuel tank.
11. Disconnect the fuel fill pipe from the fuel tank.




12. Disconnect the fuel feed pipe (2) and EVAP pipe (1) from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
13. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
14. Support the fuel tank.





Caution: Refer to Damage to Fuel Tank Straps Caution (Vehicle Damage Warnings).

15. Remove the fuel tank strap attaching bolts.
16. Remove the fuel tank straps.
17. Carefully lower the fuel tank.




18. Disconnect the EVAP vent valve electrical connector (8).
19. Disconnect the fuel tank pressure sensor electrical connector (2).
20. Disconnect the fuel sender electrical connector (1).
21. Remove the fuel tank.
22. Place the fuel tank in a suitable work area.
23. If the fuel tank is not being replaced, go to the Installation Procedure.

Disassembly Procedure




1. Cut and remove the tie (2) securing the fuel feed pipe and EVAP canister purge pipe together.
2. Remove the fuel feed pipe (1) from the fuel sender module (4) and retaining clip (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




3. Cut and remove the tie (1) securing the EVAP pipes together.
4. Disconnect the EVAP pipe assembly (3) from the tank vent valves and fuel sender. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Remove the EVAP pipe assembly (3) from the tank.
6. Remove the EVAP canister purge pipe (2) from the fuel tank.




7. Remove the EVAP vent valve (8). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement (Service and Repair).
8. Remove the fuel sender assembly (4) from the fuel tank. Refer to Fuel Sender Assembly Replacement (Service and Repair).

Assembly Procedure




1. Install the fuel sender assembly (4) to the fuel tank. Refer to Fuel Sender Assembly Replacement (Service and Repair).
2. Install the EVAP vent valve (8). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement (Service and Repair).




3. Install the EVAP canister purge pipe (2) to the fuel tank.
4. Install the EVAP pipe assembly (3) to the fuel tank.
5. Connect the EVAP pipe assembly (3) to the tank vent valves and fuel sender. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
6. Install a new tie (1) to secure the EVAP pipes together.




7. Install the fuel feed pipe (1) to the fuel sender module (4) and retaining clip (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
8. Install a new tie (2) securing the fuel feed pipe and EVAP canister purge pipe together.

Installation Procedure

1. Support the fuel tank.




2. Connect the fuel sender electrical connector (1).
3. Connect the EVAP vent valve electrical connector (2).
4. Connect the fuel pressure sensor electrical connector (8).




5. Install the fuel tank straps.

Caution: Refer to Fastener Caution (Fastener Caution).

6. Install the fuel tank strap attaching bolts and tighten to32 Nm (24 ft. lbs.).




7. Remove the caps from the fuel and EVAP pipes.
8. Connect the fuel feed pipe (1) and the EVAP pipe (2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




9. Connect the fuel fill pipe to the fuel tank. Tighten the fuel fill hose clamp to 2.5 Nm (22 in. lbs.).
10. Connect the fuel filler pipe recirculation hose to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




11. Connect the EVAP purge pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
12. Connect the EVAP canister solenoid pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
13. Connect the EVAP canister fresh air pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
14. Lower the vehicle.
15. Refill the fuel tank.
16. Install the fuel filler cap.
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
18. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
19. Use the following procedure in order to inspect for leaks:

1. Turn ON the ignition, with the engine OFF for 10 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

20. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (Service and Repair).
21. Install the frame brace. Refer to Frame Brace Replacement (Service and Repair).
22. Lower the vehicle.