Fuel Tank Removal and Installation

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING The VEHICLE.

1. Release fuel system pressure. Refer to Fuel Pressure Release Procedure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Remove fuel cap slowly to release tank pressure.
5. With vehicle on a hoist, drain fuel from tank. Drain fuel tank refer to Draining the Fuel Tank.
6. Raise and support the vehicle.

WARNING: There may be fuel in the fill tube. Remove hose carefully to reduce fuel splash.

7. Disconnect fuel tank from rubber fill hose.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

Fig. 29 Fuel Tank Straps:

8. Remove bolts from the fuel tank straps (Fig. 29).
9. Lower fuel tank and remove the EVAP line and recirculation line.
10. Remove vacuum line from LDP.

Fig. 30 Fuel Line:

11. Disconnect fuel line at the front of the fuel tank. This is a quick connect fitting (Fig. 30).

Fig. 31 Electrical Connector:

12. Unlock the electrical connector then disconnect the electrical connector (Fig. 31)
13. Remove hoses from EVAP canister.
14. Remove fuel tank from vehicle.

INSTALLATION

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING The VEHICLE.

1. Position fuel tank on transmission jack.
2. Raise fuel tank into position.
3. Connect vacuum line to LDP.
4. Install EVAP line and recirculation line.
5. Connect electrical connector (Fig. 31) and lock the connector.
6. Connect the fuel line (Fig. 30). Refer to Quick Connect Fittings.
7. Connect fuel fill tube to tank inlet. Tighten hose clamp to 3.5 Nm (31 in. lbs.) torque.
8. Position fuel tank straps. Tighten fuel tank strap bolts to 28 Nm (250 in. lbs.) torque (Fig. 29). Remove transmission jack. Ensure straps are not twisted or bent.
9. Lower vehicle.
10. Fill fuel tank, install filler cap.
11. Install the negative battery cable.
12. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
13. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.