Fuel Tank Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE
1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining Procedure.

CAUTION: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

3. Disconnect the negative battery cable.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Remove the exhaust system.
6. Remove the propeller shaft.




7. Remove the rear drive module propeller shaft guard (2) mounting bolts (1).




8. Remove the evaporative emission (EVAP) canister (4).
9. Disconnect the chassis fuel supply line (2) from the fuel tank.

NOTE: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

CAUTION: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.




10. Disconnect the fuel filler tube, EVAP vent hose, and fresh air hose from the fuel tank.
11. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.




12. Support the fuel tank.

NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

13. Remove the fuel tank strap bolts and fuel tank straps.
14. Lower the fuel tank from the underbody of the vehicle.
15. If replacing the fuel tank, remove the fuel tank module assemblies.

INSTALLATION PROCEDURE
1. If previously removed, install the fuel tank module assemblies.




2. Install the fuel tank heat shield and fuel tank assembly to the vehicle.
3. Install the fuel tank straps and the fuel tank strap-to-body bolts.

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

NOTE: Refer to Fastener Notice in Service Precautions.




4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
6. Connect the fuel filler tube to the fuel tank.

Tighten the fuel filler tube clamp to 5 N.m (44 lb in).




7. Connect the chassis fuel supply line (2) to the fuel tank.
8. Install the evaporative emission (EVAP) canister (4).




9. Install the rear drive module propeller shaft guard (2).
10. Install the rear drive module propeller shaft guard mounting bolts (1).

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

11. Install the propeller shaft.
12. Install the exhaust system.
13. Lower the vehicle.
14. Fill the fuel tank with gasoline.
15. Connect the negative battery cable.
16. Prime the fuel system:
1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
2. Repeat the previous step twice.
3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
4. If the engine does not start, repeat steps 13.1-13.3.