Removal and Replacement

Fuel Tank Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise and support the vehicle enough to access the top of the fuel tank through the wheelhouse liner. Refer to Vehicle Lifting.
4. Remove the left rear wheelhouse liner.
5. Loosen the fuel fill hose clamp (3) at the fuel tank.
6. Remove the fuel fill hose from the fuel tank.
7. Disconnect the evaporative emission (EVAP) vapor line (5) from the fuel fill neck vapor line (1).
8. Completely raise the vehicle.




9. Remove the fuel tank shield rear upper bolt.




10. Remove the fuel tank shield lower bolts (1).
11. Remove the fuel tank shield (2).
12. Position an adjustable jack under the fuel tank for support.





Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

13. Remove the upper fuel tank strap bolt.
14. Remove the upper fuel tank strap.




15. Remove the fuel tank front strap bolt.
16. Remove the fuel tank front strap.




17. Remove the fuel tank rear strap bolt.




18. Remove the fuel tank rear strap.
19. With the aid of an assistant, carefully lower the fuel tank until the electrical connections can be accessed.




20. Disconnect the following electrical connectors from the fuel tank:

* The fuel tank pressure sensor (1)
* The fuel tank module (2)

21. Disconnect the fuel feed line at the fuel tank.
22. Completely lower the fuel tank and place the fuel tank in a suitable work area.
23. If the fuel tank is not being replaced, proceed go to the Installation Procedure.

Disassembly Procedure




1. Using a flare nut wrench and a back up wrench, disconnect the fuel feed line (1) fitting from the fuel tank module.
2. Disengage and remove the fuel feed line (1) from the fuel tank.
3. Disconnect the EVAP vapor line (2) from the fuel tank vent valve, and fuel tank module.
4. Disengage and remove the EVAP vapor line (2) from the retaining clip.
5. Remove the fuel tank module.

Assembly Procedure




1. Install the fuel tank module.
2. Install and engage the EVAP vapor line (2) to the retaining clip.
3. Connect the EVAP vapor line (2) to the fuel tank vent valve, and fuel tank module.
4. Install and engage the fuel feed line (1) to the fuel tank.
5. Using a flare nut wrench and a back up wrench, Connect the fuel feed line (1) fitting to the fuel tank module.

Tighten the fitting to 30 N.m (22 lb ft).

Installation Procedure




1. With the aid of an assistant, place the fuel tank onto the jack and support the fuel tank.
2. Partially raise the fuel tank until the electrical connections can be made.
3. Connect the fuel feed line at the fuel tank.
4. Connect the following electrical connectors to the fuel tank:

* The fuel tank pressure sensor (1)
* The fuel tank module (2)




5. Install the fuel tank rear strap.




6. Install the fuel tank rear strap bolt until snug.




7. Install the fuel tank front strap.
8. Install the fuel tank front strap bolt until snug.

Notice: Refer to Fastener Notice.

9. Tighten the fuel tank strap bolts.

Tighten the bolts to 32 N.m (24 lb ft).




10. Install the upper fuel tank strap.
11. Install the upper fuel tank strap bolt.

Tighten the bolt to 32 N.m (24 lb ft).

12. Remove the adjustable jack from under the fuel tank.




13. Position the fuel tank shield (2) to the frame.
14. Install the fuel tank shield lower bolts (1).

Tighten the bolts to 10 N.m (89 lb in).




15. Install the fuel tank shield rear upper bolt.

Tighten the bolt to 10 N.m (89 lb in).

16. Lower the vehicle only enough to gain access to the fuel tank through the wheelhouse.




17. Install the fuel fill hose to the fuel tank. Position the fuel fill hose orientation notch (2) in line with the tab (4) on the fuel tank.
18. Tighten the fuel fill hose clamp (3).

Tighten the clamp to 2.5 N.m (22 lb in).

19. Connect the EVAP vapor line (5) to the fuel fill neck vapor line (1).
20. Install the left rear wheelhouse liner.
21. Lower the vehicle.
22. Refill the fuel tank.
23. Install the fuel fill cap.
24. Inspect for leaks.

1. Turn ON the ignition, with the engine OFF for 10 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.