Fuel Tank - Front Wheel Drive (FWD)

FUEL TANK - FRONT WHEEL DRIVE (FWD)

Front Wheel Drive (FWD) Vehicles (Part 1):

Front Wheel Drive (FWD) Vehicles (Part 2):

All Wheel Drive (AWD) Vchicles:

Exploded View

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in 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 always present and may be ignited. Failure to follow these instructions can result in personal injury.
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, and possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Disconnect the battery ground cable.
4. Drain the fuel tank.







5. CAUTION: Some residual fuel may remain in the fuel tank filler pipe after draining the fuel tank. Carefully drain any remaining fuel into a suitable container.

Release the clamp and disconnect the fuel tank filler pipe hose from the fuel tank.
- To install, tighten to 4 Nm (35 lb-in).







6. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling.
7. Support the exhaust system with suitable jack stands.







8. Remove the 2 nuts and disconnect the catalytic converter from the exhaust flexible pipe.
- To install, tighten to 40 Nm (30 lb-ft).
- Discard the catalytic converter flange gasket.

Vehicles with 2.3L engine







9. With the aid of an assistant, release the 4 exhaust hangers and remove the exhaust system.

Vehicles with 3.0L and 3.5L engines







10. With the aid of an assistant, release the 5 exhaust hangers and remove the exhaust system.

All vehicles







11. Remove the 4 nuts, 2 clips and 2 pin-type retainers from the fuel tank heat shield.
- Remove the fuel tank heat shield.

12. Install a suitable lifting device below the fuel tank.
13. Remove the 4 bolts and the 2 fuel tank mounting straps.
- To install, tighten to 47 Nm (35 lb-ft).

14. Carefully lower the fuel tank from the vehicle.
15. To install, reverse the removal procedure.
- Install a new catalytic converter flange gasket.