Fuel Tank Replacement

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Remove the wheel house filler pipe opening cover (2).
5. Disconnect the fuel fill hose from the fuel fill pipe.
6. Remove the rear suspension support assembly.




7. Disconnect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar).




8. Disconnect the EVAP pipe (2) from the EVAP canister.




9. Remove the fuel and EVAP retainer from the frame.




10. Disconnect the fuel tank electrical connector.
11. Disconnect the fuel tank electrical harness from the retainers.




12. Remove the fuel tank strap bolts (4).
13. Remove the fuel tank (5).

DISASSEMBLE PROCEDURE




1. If the fuel tank is not being replaced refer to the Installation Procedure.
2. Remove the fuel pipes (2,3) and the EVAP pipe (1).
3. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.




4. Remove the fuel filler hose clamp (2).
5. Remove the fuel filler hose from the fuel tank (3).

ASSEMBLE PROCEDURE




1. Install the fuel filler hose to the fuel tank (3). Align the dot on the hose to the parting line on the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the fuel filler hose clamp (2).

Tighten
Tighten the clamp to 3.5 N.m (31 lb in).




3. Install the fuel sender assembly.
4. Install the fuel pipes (2,3) and the EVAP pipe (1).

INSTALLATION PROCEDURE




1. Position and support the fuel tank (5) with the aid of an assistant

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the fuel tank straps (2).
3. Install the fuel tank strap bolts (4).

Tighten
Tighten the fuel tank strap bolts to 42 N.m (31 lb ft).




4. Connect the fuel tank electrical connector.
5. Install the fuel tank electrical harness into the retainers.




6. Install the fuel and EVAP retainer to the frame.




7. Connect the EVAP pipe (2) to the EVAP canister.




8. Connect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar).




9. Install the rear suspension support assembly.
10. Connect the fuel filler hose to the fuel filler pipe.

Tighten
Tighten the clamp to 3.5 N.m (31 lb in).

11. Install the wheelhouse filler pipe opening cover (2).
12. Lower the vehicle.
13. Add fuel to the fuel tank.
14. Install the fuel tank filler pipe cap.
15. Connect the negative battery cable.
16. Inspect for leaks.
16.1. Turn ON the ignition switch for 2 seconds.
16.2. Turn OFF the ignition switch for 10 seconds.
16.3. Turn ON the ignition switch.
16.4. Inspect for fuel leaks.
17. Install the fuel injector sight shield.