Removal and Replacement

FUEL TANK

Exploded View

Front Wheel Drive (FWD) Vehicle (Part 1):

Front Wheel Drive (FWD) Vehicle (Part 2):

All Wheel Drive (AWD) Vehicle (Part 1):

All Wheel Drive (AWD) Vehicle (Part 2):

All Vehicles (Part 1):

All Vehicles (Part 2):

Removal and Installation

WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
- Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

All vehicles
1. Drain the fuel tank.

All wheel drive (AWD) vehicles
2. Remove the muffler and tailpipe.
3. Remove the driveshaft.

All vehicles
4. Install a suitable lifting device under the fuel tank.
5. Disconnect the fuel tank wiring harness electrical connector.
6. Disconnect the fuel tank pressure (FTP) sensor electrical connector.
7. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling.
8. Release the clamp and disconnect the fuel tank filler pipe hose from the fuel tank.
- To install, tighten to 4 Nm (35 lb-in).

9. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling.
10. Remove the 2 parking brake cable bracket bolts and position cables aside.
- To install, tighten to 23 Nm (17 lb-ft).

11. CAUTION: Remove all bolts prior to lowering the fuel tank. Fuel tank damage can occur if all of the bolts are not removed.

Remove the 2 fuel tank bracket bolts and the 4 fuel tank bolts.
- To install, tighten to 25 Nm (18 lb-ft).

12. NOTE: All wheel drive (AWD) vehicles require the fuel tank to be positioned forward, past the rear differential unit (RDU), then lowered.

Completely lower and remove the fuel tank.

13. To install, reverse the removal procedure.