Fuel Tank Replacement

Fuel Tank Replacement

Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution.

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Release (With CH 48027) Fuel Pressure Release (Without CH 48027).
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Disconnect the fuel tank vent pipe quick connect fittings (1, 4).
5. Loosen the fuel fill pipe hose clamp (2) at the fuel tank.
6. Remove the fuel fill pipe hose from the fuel tank.




7. Disconnect the fuel tank electrical connector (1) from the pass thru connector.




8. Remove the exhaust pipe insulators from the underbody hangers.
9. Remove the muffler insulators from the underbody hanger and slowly lower the exhaust in order to allow it to rest on the rear axle beam.




10. Place an adjustable jack under the fuel tank.
11. Remove the fuel tank strap bolts.
12. Remove the fuel tank straps.
13. Using the adjustable jack, carefully lower the fuel tank away from the vehicle.
14. With the aid of an assistant, place the fuel tank on a suitable work surface.




15. If replacing the fuel tank perform the following steps, remove the fuel tank vent pipe.




16. Remove the fuel feed intermediate pipe.




17. Remove the fuel tank vent pipe.




18. Disconnect and remove the fuel tank electrical harness.
19. Remove the fuel tank module.

Installation Procedure




1. If the fuel tank was replaced perform the following steps, install the fuel tank module.
2. Install and connect the fuel tank electrical harness.




3. Install the fuel tank vent pipe.




4. Install the fuel feed intermediate pipe.




5. Install the fuel tank vent pipe.




6. With the aid of an assistant, place the fuel tank on the suitable jack.
7. Using the adjustable jack, carefully raise the fuel tank into position.
8. Position the fuel tank straps.

Notice: Refer to Fastener Notice.

9. Install the fuel tank strap bolts.

Tighten the bolts to 45 N.m (33 lb ft).

10. Remove adjustable jack from under the fuel tank.




11. Raise the exhaust and install the muffler insulators to the underbody hangers.
12. Install the exhaust pipe insulators to the underbody hangers.




13. Connect the fuel tank electrical connector (1) to the pass thru connector.




14. Install the fuel fill pipe hose to the fuel tank.
15. Tighten the fuel fill pipe hose clamp (2) at the fuel tank.

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

16. Connect the fuel tank vent pipe quick connect fittings (1, 4).
17. Lower the vehicle.
18. Refill the fuel tank.
19. Connect the negative battery cable.
20. 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.