Fuel Tank Unit: Service and Repair

REMOVAL
1. Release fuel pressure. Refer to Fuel System Pressure Release Procedure.
2. Remove Fuel Tank.

WARNING: The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

3. Disconnect fuel line from fuel pump module by depressing quick connect retainers with thumb and fore finger.
4. Slide fuel pump module electrical connector lock to unlock.
5. Disconned the electrical connection from the fuel pump module, by pushing down on connector retainer and pulling connector off of module.

Fig 10 Fuel Tank Locknut:

6. Use Special Tool 6856 to remove fuel pump module locknut (Fig. 10).
7. Remove fuel pump and 0-ring seal from tank. Discard old seal.

INSTALLATION
1. Wipe seal area of tank clean and place a new seal in position in the tank opening.

Fig 11 Fuel Tank Locator Notch:

2. Position fuel pump in the tank. Make sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank (Fig. 11).
3. Position the locknut over the fuel pump module.
4. Tighten the locknut using Special Tool 6856 to 55 Nm (40.5 ft lb).

CAUTION: Over tightening the pump lock ring may result in a leak.

5. Raise the fuel tank on the transmission stand.
6. Install fuel pump electrical connector into hole in the body
7. Connect the purge and vent lines.
8. Raise tank into position and install tank straps.
9. Install the fuel filler tube and tighten the clamp.
10. Reposition the stabilizer bar and install bolts.
11. Lower vehicle.
12. Connect the fuel pump electrical connector that is in the rear seat.
13. Install the rear seat.
14. Connect the battery cable.
15. Fill fuel tank. Use the DRB scan tool to pressurize the fuel system. Check for leaks.