Removal and Replacement

Fuel Tank Replacement (AWD)

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.

Notice: 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.
2. Raise and suitably support the vehicle.
3. Remove the propeller shaft from the vehicle.
4. Remove the catalytic converter and intermediate pipe assembly from the vehicle.
5. Remove the 4 rivets (2) securing the rear exhaust heat shield (3) to the vehicle.
6. Remove the rear exhaust heat shield (3) from the fuel tank (1).






7. Remove the 3 bolts (1) securing the parking brake cable (2) on the left side of the vehicle.






8. Remove the 3 bolts (1) securing the parking brake cable (3) on the evaporative emission (EVAP) canister (2) side of the vehicle.






9. Disconnect the EVAP drain hose (2) from the EVAP canister (1).






10. Disconnect the EVAP purge and vent lines (3) from the EVAP canister (2).
11. Remove the EVAP lines (3) from the body clip (1) and swing the lines away from the fuel tank.
12. Remove the EVAP canister (2).






13. Disconnect the fuel supply line.






14. Loosen the fuel filler hose clamp (1).
15. Disconnect the fuel filler hose (2) from the fuel tank.






16. Disconnect the 2 filler pipe vent lines (2) from the fuel tank.
17. Support the fuel tank with a transmission jack or other suitable fixture.
18. Remove the four bolts (3) and the two fuel tank straps (1) from the vehicle.
19. Remove the fuel tank from the vehicle.
20. If replacing the fuel tank, remove all lines, hoses, and the FLVV, and install on the replacement fuel tank.

Installation Procedure






1. Install the fuel tank to the vehicle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the 2 fuel tank straps (1) to the vehicle with the four bolts (3). Tighten the bolts to 39 Nm (29 lb ft).
3. Connect the 2 filler pipe vent lines (2) to the fuel tank.






4. Connect the fuel filler hose (2) to the fuel tank.
5. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).
6. Connect the fuel supply line.
7. Install the EVAP canister to the vehicle.






8. Secure the EVAP purge and vent lines (3) to the chassis with the body clip (1).
9. Connect the EVAP lines (3) to the EVAP canister (2).






10. Connect the EVAP drain hose (2) to the EVAP canister (1).






11. Secure the parking brake cable (3) on the EVAP canister (2) side of the vehicle with 3 bolts (1). Tighten the bolts to 5.4 Nm (48 lb in).






12. Secure the parking brake cable (2) on the left side of the vehicle with 3 bolts (1). Tighten the bolts to 5.4 Nm (48 lb in).






13. Install the rear exhaust heat shield (3) to the fuel tank (1).
14. Secure the rear exhaust heat shield (3) with four rivets (2).
15. Install the propeller shaft.
16. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle.
17. Lower the vehicle.






18. Install the fuel supply line (1) to the fuel sender fitting.
19. Secure the fuel supply line (1) with the retaining clip (2).






20. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
21. Connect the fuel tank pressure (FTP) sensor electrical connector (1) to the fuel sender assembly.
22. Add fuel to the fuel tank.
23. Connect the negative battery cable. Tighten the retainer for the negative battery cable terminal to 15 Nm (11 lb ft).
24. Pressurize the fuel system and check for leaks.
25. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
26. Install the access panel to the rear seat floor.
27. Install the sill plate to the left side door opening.
28. Install the rear seat bottom cushion.