Fuel Tank Replacement (Rear Tank)

Fuel Tank Replacement (Dual Tanks - Rear)







REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
Fuel Pressure Release
2. Remove the spare tire stowage lock cylinder.







3. Remove the spare tire.
4. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
Procedures
5. Remove the rear exhaust insulator.







6. Remove the spare tire hoist crossmember bolts and crossmember.







7. Loosen the fuel tank fill hose clamp at the front tank.
8. Separate the fill hose from the front tank.







9. Loosen the fuel tank fill pipe hose clamp at the rear tank.
10. Separate the fill pipe hose from the rear tank.
11. Loosen the vent hose clamp at the rear tank.
12. Separate the vent hose from the rear tank.







13. Support the fuel tank with a suitable jack.
14. Remove the fuel tank strap bolts.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions Vehicle Damage Warnings.

15. Remove the fuel tank straps.







16. Open the retaining clip.
17. Remove the fill hose from the clip.







18. Disconnect the EVAP pipes (2).
19. Disconnect the fuel pipe at the fuel sending unit (1).
20. Cap the EVAP and fuel pipes, in order to prevent possible EVAP/fuel system contamination.
21. With the aid of an assistant, partially lower the rear tank.







22. Disconnect the fuel tank electrical connectors.
23. Completely lower the fuel tank.
24. With the aid of an assistant, remove the tank from the jack.
25. If necessary, remove the sending unit.







INSTALLATION PROCEDURE
1. If necessary, install the sending unit.
2. With the aid of an assistant, install the tank onto the jack.
3. Raise the fuel tank until the electrical connection can me made.
4. Connect the fuel tank electrical connectors.







5. Remove the caps from the EVAP and fuel pipes.
6. Connect the fuel pipe at the fuel sending unit (1).
7. Connect the EVAP tubes (2).







8. Install the hose to the retaining clip.
9. Close the retaining clip.
10. Completely raise the fuel tank.







11. Install the fuel tank straps.
12. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to .....................................40 N.m (30 lb ft).

13. Remove the jack from the fuel tank.







14. Install the vent hose to the rear tank.
15. Tighten the vent hose clamp at the rear tank.
16. Install the fill pipe hose to the rear tank.
17. Tighten the fuel tank fill pipe hose clamp at the rear tank.

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







18. Install the fill hose to the front tank.
19. Tighten the fill hose clamp at the front tank.

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







20. Install the spare tire hoist crossmember and bolts.

Tighten
Tighten the bolts to ......................................50 N.m (37 lb ft).







21. Install the rear exhaust insulator.
22. Lower the vehicle.
23. Install the spare tire.







24. Install the spare tire stowage lock cylinder.
25. Refill the fuel tank.
26. Install the fuel fill cap.
27. Connect the negative battery cable.
28. Use the following procedure in order to inspect for leaks:
28.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
28.2. Turn the ignition OFF for 10 seconds.
28.3. Turn the ignition ON, with the engine OFF.
28.4. Inspect for fuel leaks.