Fuel Tank Removal and Installation

FUEL TANK

Special Tools:

WARNING:

- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.


- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are present and may be ignited. Failure to follow these instructions can result in personal injuries.


- Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in possible personal injury.



1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel pressure.
3. Disconnect the battery ground cable.
4. Remove the fuel tank filler cap.






5. Insert the special tool into the fuel tank filler pipe until it reaches the fuel tank spout.
6. Attach the Fuel Storage Tanker to the Fuel Drain Hose and remove any residual fuel in the fuel tank filler neck.






7. Using suitable hose pinching pliers, clamp the fuel tank filler hose in the location shown.







8. Release the clamp to the fuel tank filler tube and disconnect the hose.
9. Disconnect the 2 evaporative emission tube quick connect couplings.







10. Disconnect the fuel tank harness electrical connector.
11. Disconnect the fuel filter inlet tube quick connect coupling.
12. Position a suitable lifting device under the fuel tank.
13. Remove the 2 fuel tank support strap bolts.
- To install, tighten to 35 Nm (26 lb-ft).
14. Position the fuel tank support straps aside.
15. Lower the fuel tank enough to access the fuel pump module.
16. Clean the area around the fuel pump mounting flange.
17. Disconnect the fuel pump module electrical connector.
18. Disconnect the fuel supply tube quick connect coupling at the fuel filter inlet.






19. Using the special tool, remove the fuel pump module retaining ring.
20. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm, filter and convolute hoses.

Turn the fuel pump module counterclockwise and the fuel pump module will release from the locking tabs.
21. Remove the fuel pump module from the fuel tank.
- Discard the O-ring seal.
22. Using the special tool, drain the fuel from the fuel tank.
- Install a new O-ring before installing the fuel pump module.
23. Finish lowering the fuel tank and remove from the lifting device.
24. To install, reverse the removal procedure.
- Install a new O-ring before installing the fuel pump module.
- Turn the ignition key to the ON position to pressurize the fuel system.
- Visually inspect the fuel system for leaks.