Fuel Tank Replacement

Fuel Tank Replacement

Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Disconnect the fuel pump module fuel feed (2) and return (1) line quick connect fittings from the fuel filter.
5. Cap or plug the fuel filter feed and return line fittings in order to prevent fuel loss and/or system contamination.
6. Cap or plug the fuel pump module feed and return lines in order to prevent fuel loss and/or system contamination.




7. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fittings (2, 3) from the EVAP canister.
8. Cap or plug the EVAP lines and canister fittings in order to prevent system contamination.




9. Disconnect the fuel tank vent line quick connect fitting (2) from the fill pipe recirculation line.
10. Loosen the fuel fill hose clamp (3) at the fuel tank.
11. Remove the fuel fill hose from the fuel tank.
12. Cap or plug the fuel tank opening and vent line in order to prevent fuel loss and/or system contamination.




13. Disconnect the fuel tank harness electrical connectors (1 and 3) from the body harness pass through connector (2).




14. Disconnect the fuel tank harness electrical connector (1) from the fuel tank pressure sensor.
15. Disconnect the fuel tank harness electrical connector (2) from the EVAP canister vent solenoid valve.
16. Remove the harness retainers from the underbody.




17. Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust, allowing it to rest on the rear axle beam.




18. Use a suitable jack to support the fuel tank during the fuel tank strap and tank removal.
19. Remove the left (L) fuel tank strap bolts and strap.
20. Remove the right (R) fuel tank strap bolts and strap.
21. In order to clear the exhaust muffler assembly, slowly lower the right side of the fuel tank. Use care when feeding the fuel, EVAP lines, and electrical harness around rear axle.
22. Once the fuel tank is clear of the right frame rail, remove the fuel tank down and toward the right side of the vehicle.
23. If the fuel tank is be replaced, remove the fuel pump module. Refer to Fuel Pump Module Replacement.

Installation Procedure




1. If the fuel tank was replaced, install the fuel pump module. Refer to Fuel Pump Module Replacement.
2. Use a suitable jack to support the fuel tank during the fuel tank and strap installation.
3. Install the left side of the fuel tank over the exhaust muffler assembly.
4. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care when feeding the fuel, EVAP lines, and electrical harness over the rear axle.
5. Install the right (R) fuel tank strap and bolts.
6. Install the left (L) fuel tank strap and bolts.

Notice: Refer to Fastener Notice.

7. Tighten the fuel tank strap bolts.

Tighten the bolts to 25 N.m (18 lb ft).




8. Raise the exhaust muffler assembly into position and install the insulators to the underbody hanger.




9. Connect the fuel tank harness electrical connector (1) to the fuel tank pressure sensor.
10. Connect the fuel tank harness electrical connector (2) to the EVAP canister vent solenoid valve.
11. Install the harness retainers to the underbody.




12. Connect the fuel tank harness electrical connectors (1 and 3) to the body harness pass through connector (2).




13. Remove the cap or plug from the fuel tank and vent line openings.
14. Connect the fuel fill hose to the fuel tank. Align the 1/2D1/2 notch on the fill hose (1) with the 1/2D1/2 notch on the fuel tank (1).

Notice: Refer to Component Fastener Tightening Notice.

15. Tighten the fuel fill hose clamp (3).

Tighten the clamp to 4.5 N.m (40 lb in).

16. Connect the fuel tank vent line quick connect fitting (2) to the fill pipe recirculation line.




17. Remove the caps or plugs from the EVAP lines.
18. Connect the fuel tank EVAP line quick connect fittings (2, 3) to the EVAP canister.




19. Remove the caps or plugs from the fuel pump module fuel feed and return lines.
20. Remove the caps or plugs from the fuel filter feed and return line fittings.
21. Connect the fuel pump module fuel feed (2) and return (1) line quick connect fittings to the fuel filter.
22. Lower the vehicle.
23. Refill the fuel tank.
24. Connect the negative battery cable.
25. Inspect for fuel leaks using the following procedure:

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