Fuel Tank Replacement

Fuel Tank Replacement

Special Tools

* CH-807 - Closer Plug

* EN-6015 - Closer Plug

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Warning: Refer to Fuel Vapors in Evaporative Emission Components Warning Fuel Vapors in Evaporative Emission Components Warning.


Warning: Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


Warning: Refer to Safety Goggles and Fuel Warning Safety Goggles and Fuel Warning.


1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Relief the fuel pressure. Refer to Fuel Pressure Relief Service and Repair.

3. Drain the fuel tank. Refer to Fuel Tank Draining Procedures.

4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.




5. Disconnect the fuel pressure wiring harness plug (2) from the fuel pressure sensor.

6. Open the rear bracket clip (3).

7. Unclip the fuel feed pipe (4) from the rear bracket clip (3).

8. Disconnect the fuel tank feed pipe connector (1) from the fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

9. Close the fuel feed pipe and the fuel tank feed pipe with the EN-6015 - plugs.




10. Unclip the evaporative emission canister purge vent pipe - chassis (3) from the rear bracket clip (2).

11. Disconnect the evaporative emission canister purge vent pipe connector (1) from the evaporative emission canister purge vent pipe - chassis (3). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

12. Close the evaporative emission canister purge pipe and evaporative emission canister purge vent pipe - chassis with the EN-6015 - plugs.




13. Remove the clamp (2).

14. Remove the fuel tank filler hose (3) from the fuel tank filler pipe (1).

15. Disconnect the fuel tank filler vent pipe (4). Refer to Fuel Tank Filler Pipe Replacement Fuel Tank Filler Pipe Replacement.





Caution:
When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.

16. Place a suitable adjustable jack under the fuel tank.

Note: The washers (2) will remain on the bolts (3).

17. Loosen the 2 fuel tank strap bolts (3).

18. Remove the 2 fuel tank straps (4) in conjunction with the bolts (3) and washers (2).





Note: A second technician is required.

19. Retract the jack stepwise, until you can remove the fuel tank fuel pump module wiring harness plugs.

20. Disconnect the fuel tank fuel pump module wiring harness (1) from the fuel tank fuel pump module (2).

21. Unclip the fuel tank fuel pump module wiring harness (1) from the 2 bracket clips (3).

22. Remove the evaporative emission canister. Refer to Evaporative Emission Canister Replacement Service and Repair.

23. Remove the fuel tank, by retracting the jack.

Disassemble Procedure

1. Remove the fuel feed pipe - tank. Refer to Fuel Feed Pipe Replacement - Tank Side Fuel Feed Pipe Replacement - Tank Side.

2. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement Fuel Tank Fuel Pump Module Replacement.

3. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement (2.4L LEA) Fuel Tank Heat Shield ReplacementFuel Tank Heat Shield Replacement (2.0L LHU) Fuel Tank Heat Shield Replacement.

4. Remove the 2 fuel tank baffles if equipped. Refer to Fuel Tank Baffle Replacement Fuel Tank Baffle Replacement.

Assemble Procedure

1. Install the 2 fuel tank baffles if equipped. Refer to Fuel Tank Baffle Replacement Fuel Tank Baffle Replacement.

2. Install the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement (2.4L LEA) Fuel Tank Heat Shield ReplacementFuel Tank Heat Shield Replacement (2.0L LHU) Fuel Tank Heat Shield Replacement.

3. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement Fuel Tank Fuel Pump Module Replacement.

4. Install the fuel feed pipe - tank. Refer to Fuel Feed Pipe Replacement - Tank Side Fuel Feed Pipe Replacement - Tank Side.

Installation Procedure

1. Place the fuel tank on a jack.





Note: A second technician is required.

2. Extend the jack stepwise, until you can install the fuel tank fuel pump module wiring harness (1).

3. Install the evaporative emission canister. Refer to Evaporative Emission Canister Replacement Service and Repair.

4. Connect the fuel tank fuel pump module wiring harness (1) to the fuel tank fuel pump module (2).

5. Clip the fuel tank fuel pump module wiring harness into the 2 bracket clips (3).

6. Install the fuel tank, by extending the jack.




7. Install the 2 fuel tank straps (1).

Caution: Refer to Fastener Caution Fastener Caution.

8. Install the 2 fuel tank strap bolts (2) and tighten to 20 Nm (15 lb ft).

9. Lower and remove the jack.




10. Connect the fuel tank filler vent pipe (4). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

11. Install the fuel tank filler hose (3) to the fuel tank filler pipe (1).

12. Install the clamp (2).




13. Remove the EN-6015 - plugs from the emission canister fuel vent pipe and the fuel tank vent pipe.

14. Connect the emission canister fuel vent pipe (1) to the fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

15. Clip the fuel vent pipe (3) into the rear bracket clip (2).




16. Remove the EN-6015 - plugs from the fuel feed tank pipe and the fuel feed pipe.

17. Connect the fuel tank feed pipe connector (1) to the fuel feed pipe (4). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

18. Clip the fuel feed pipe into the rear bracket clip (3).

19. Close the rear bracket clip (3).

20. Lower and unsupport the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair

21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.