Fuel Tank Removal and Installation

Removal


NOTE: This removal/installation procedure is applicable to all tank assembly variants.


1. Remove the battery. Refer to 'Battery, Service and Repair.' Service and Repair
2. Remove the trunk floor carpet.
3. Remove the trunk front liner. Refer to 'Body and Frame, Doors, Hood and Trunk, Trunk/Liftgate.' Service and Repair
4. Remove the rear lamp assembly interior trim finisher.
5. Remove the trunk seal retainer.
6. Remove the trunk side liner, lefthand. Refer to 'Body and Frame, Doors, Hood and Trunk, Trunk/Liftgate.' Service and Repair

7. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT ALL 'SERVICE PRECAUTIONS' ARE READ AND UNDERSTOOD.

Remove the trunk side liner, righthand. Refer to 'Body and Frame, Doors, Hood and Trunk, Trunk/Liftgate.' Service and Repair

8. Drain the fuel tank using a suitable suction pump/tanker. If the On-board Refueling Vapor Recovery (ORVR) system is fitted, Refer to 'Fuel Tank, Fuel Tank Drain Procedure For ORVR System.' Service and Repair






9. From under the vehicle, identify the fuel feed and return tank/pipe connections which are located above and slightly to the rear of the rear axle assembly.

Locate the fuel feed pipe.
Locate the fuel return pipe.







10. Disconnect the fuel feed and return pipes from the fuel tank

Fit special tool JD-203 around the pipe as shown. Press the tool in between the fuel pipe and tank connector to release the quick-fit tangs. While holding the tool firmly in, pull out the fuel pipe.
Repeat for the second pipe.
Plug the tank outlet connectors and the fuel pipes.







11. From the underside of the vehicle, release the fuel filler latch box drain pipe from the clip on the spare wheel well.







12. Disconnect and reposition the trunk harness if it is routed between the filler tube and the tank breather or pressure relief pipe.

Disconnect the lefthand rear lamp harness connector.
Disconnect the fuel flap lock actuator connector.
If fitted, disconnect the lefthand side marker lamp connector and harness from the underside of the vehicle. Withdraw the marker lamp harness and grommet through the trunk floor access hole.
Release the harness securing clip from the mounting bracket.
Withdraw the trunk harness from between the filler tube and the breather pipe or pressure relief pipe.







13. Disconnect the tank harness connections

If fitted, disconnect the wiring to the accelerometer.
Disconnect the wiring to the fuel level sensor harness.
Disconnect the wiring to the fuel pump connector.
If fitted, disconnect the wiring to the pressure sensor connector.







14. Remove fuel filler latch box drain pipe.

Cut and remove the ratchet strap securing the drain pipe to the filler tube.
Disconnect the drain pipe from the fuel filler latch box.
Pull the drain pipe through the body grommet and remove.







15. Disconnect the vapor outlet pipe.

Release the quick-fit coupling
Plug the vapor pipes.







16. Disconnect the fuel filler latch box from the filler tube.

Open the fuel filler flap and remove the filler cap.
Remove the spring ring securing the fuel filler latch box to the filler neck.
Pull the fuel filler latch box free of the filler tube.







17. Remove the tank retaining straps.

Slacken the clamp nuts and bolts securing the two fuel tank retaining straps to the lower brackets (lefthand retaining strap only shown).
Remove the bolts securing the two lower brackets to the vehicle body.
Tape or tie the two retaining straps/brackets to the rear scuttle to allow tank removal.







18. On non-ORVR vehicles, disconnect the trunk lid lefthand strut rear pivot.

Place a suitable support under trunk lid or tie to exterior mirror.
Using a screwdriver, release clip at rear end of strut, withdraw end from trunk lid pivot and lower strut.







19. Disconnect the tank ground cable from the vehicle body.
20. Remove the tank from the vehicle.
21. Drain any remaining fuel from the tank.

Installation
1. Fit the fuel tank assembly.







2. Re-connect the tank ground cable to the vehicle and tighten to the specified torque.
3. On non-ORVR fuel tanks, position the trunk lid lefthand strut between the filler tube and the breather pipe.
4. Fully seat the tank into position, ensuring that no harness wiring is trapped.







5. On non-ORVR vehicles, reconnect the trunk lid lefthand strut rear pivot.

Fit the retaining clip on to the end of the trunk lid strut and fit the strut to the trunk lid pivot.
Re-position retaining clip to secure the strut.
Remove any temporary trunk lid supports and check that the lid operates correctly.







6. Fit the tank retaining straps and lower brackets and tighten to the specified torque.

Secure the lower brackets to the body.
Tighten the clamp nuts and bolts.







7. Connect the filler neck to the fuel filler latch box seal.

Fit the fuel filler latch box seal over the filler neck.
Secure with the spring ring
Fit the fuel filler cap.







8. Connect the vapor outlet pipe.

Unplug the vapor pipes.
Reconnect the tank and underfloor vapor pipes via the quick-fit coupling







9. Fit the fuel filler latch box drain pipe.

Feed the drain pipe through the floor grommet.
Connect the drain pipe to the fuel filler latch box stub pipe.
Tie the drain pipe to the filler tube using a ratchet strap. Trim strap.







10. Reconnect the trunk harness connections.

If fitted, connect the wiring to the accelerometer.
Connect the wiring to the fuel level sensor harness.
Connect the wiring to the fuel pump connector.
If fitted, connect the wiring to the pressure sensor connector.







11. Reconnect the lefthand side trunk harness if it has been necessary to move it for access. Route the harness behind both the filler tube and breather or pressure relief pipe.

Fit the harness securing clip to the mounting bracket.
Connect the fuel flap lock actuator connector.
Connect the lefthand rear lamp harness connector.
If applicable, feed the side marker lamp harness through the access hole in the floor and reseat the sealing grommet.
On the underside of the vehicle, fit the side marker lamp connector and fix the harness to the securing clips.







12. On the underside of the vehicle, fit the drain pipe to the securing clip.







13. On the underside of the vehicle, reconnect the fuel feed and return pipes.

Remove the plugs from the tank and fuel feed and return pipes.
Push the fuel feed pipe into the quick-fit tank connector. Ensure the pipe is fully home.
Push the fuel return pipe into the quick-fit tank connector. Ensure the pipe is fully home.

14. Fit the trunk side liner, lefthand. Refer to 'Body and Frame, Doors, Hood and Trunk, Trunk/Liftgate.' Service and Repair
15. Fit the trunk side liner, righthand. Refer to 'Body and Frame, Doors, Hood and Trunk, Trunk/Liftgate.' Service and Repair
16. Fit the trunk seal retainer.
17. Fit the rear lamp assembly interior trim finisher.
18. Fit the trunk front liner. Refer to 'Body and Frame, Doors, Hood and Trunk, Trunk/Liftgate.' Service and Repair
19. Fit the trunk floor carpet.
20. Ensure that the fuel feed pipes in the engine compartment are reconnected after tank draining.
21. Re-fit the battery. Refer to 'Battery, Service and Repair, Battery Reconnection Procedure.' Service and Repair
22. Carry out a leak test of the evaporative emissions system.