Fuel Tank: Service and Repair

REMOVAL
1. Release fuel system pressure. Refer to the Fuel System Pressure Release Procedure.
2. Disconnect negative cable from battery.
3. Pull back the trunk carpeting for access to the access panel of the fuel pump module.
4. Remove the access panel for fuel pump.
5. Disconnect the fuel lines.
6. Remove rubber plug for access to fuel pump electrical connector.
7. Disconnect the fuel pump electrical connector.
8. Remove the fuel pump module retaining nut.
9. Remove the fuel pump module.
10. Drain the fuel tank.
11. Raise and support vehicle
12. Remove rear tires.
13. Remove transaxle, refer to the Transaxle for Removal/Installation.
14. Remove the fuel filler hose clamps.

Fig. 27 Fuel Filler Hose:

15. Remove fuel filler hose from fuel tank (Fig. 27).
16. Disconnect fuel supply tube and the fuel return tube. Refer to Quick Connect Fittings.
17. Remove fuel lines from vehicle.
18. Remove the 2 rear fuel tank strap bolts at the rear support.

Fig. 28 Removed Electrical Connector:

19. Reposition electrical harness from frame rail (Fig. 28).
20. Remove rear support retaining nuts.
21. Remove rear support.
22. Remove front support retaining bolts.
23. Remove front support and fuel tank straps.
24. Reposition fuel tank to access the vapor canister mount.
25. Remove brake line retainer bolt at canister mount.
26. Remove canister and mount.
27. Push up and over on left side of tank. Lower fuel tank on the right side. Remove fuel tank from vehicle.

INSTALLATION
1. Reverse procedure for installation.
2. Install tank into vehicle.
3. Reposition fuel tank to access the vapor canister mount.
4. Install EVAP canister and tighten bolts.
5. Install brake line retainer bolt at canister mount.
6. Install front support and fuel tank straps.
7. Install front support retaining bolts.
8. Install rear support.
9. Install rear support retaining nuts.
10. Reposition electrical harness to frame rail (Fig. 28).
11. Install the 2 rear fuel tank strap bolts at the rear support.
12. Install fuel lines to vehicle.
13. Connect fuel supply tube and the fuel return tube. Refer to Quick Connect Fittings.
14. Install fuel filler hose to fuel tank (Fig. 27).
15. Install the fuel filler hose clamps and tighten.
16. Install transaxle, refer to the Transaxle for Removal/Installation.
17. Install rear tires.
18. Lower vehicle
19. Install the fuel pump module.
20. Install the fuel pump module retaining nut.
21. Connect the fuel pump electrical connector.
22. Install the rubber plug for access to fuel pump electrical connector.
23. Connect the fuel lines.
24. Install the access panel for fuel pump.
25. Install the trunk carpeting.
26. Connect negative cable to battery.
27. Use the DRB to check for fuel leaks.