Removal and Replacement
FUEL TANKExploded View
106L (28 Gal) Fuel Tank (Part 1):
106L (28 Gal) Fuel Tank (Part 2):
127L (33.5 Gal) Fuel Tank (Part 1):
127L (33.5 Gal) Fuel Tank (Part 2):
Removal and Installation
All fuel tanks
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.
- 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.
- 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.
- 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.
- 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.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain the fuel tank.
106L (28 gal) fuel tank
3. If equipped, remove the 4 nuts and the fuel tank skid plate.
- To install, tighten to 20 Nm (15 lb-ft).
127L (33.5 gal) fuel tank
4. If equipped, remove the 5 nuts and the fuel tank skid plate.
- To install, tighten to 20 Nm (15 lb-ft).
All fuel tanks
5. Disconnect the fuel tank filler pipe vapor tube from the evaporative emissions (EVAP) canister fresh air tube, and the fuel tank filler pipe vent tube-to-fuel tank pressure sensor and vapor tube assembly quick connect coupling in the rear of the fuel tank.
6. Disconnect the fuel filter outlet tube-to-fuel tube spring lock coupling, EVAP canister fresh air tube-to-dust separator quick connect coupling and the fuel tank pressure sensor and vapor tube assembly-to-EVAP canister quick connect coupling in the front of the fuel tank.
7. Remove the sway bar bracket nuts and let the sway bar hang down.
- To install, tighten to 48 Nm (35 lb-ft).
8. CAUTION: Do not support the fuel tank directly beneath the fuel pump (FP) mounting area. Damage to the fuel pump assembly can occur.
Position a suitable jack under the fuel tank.
127L (33.5 gal) fuel tank
9. Remove the center fuel tank support strap bolt.
- To install, tighten to 40 Nm (30 lb-ft).
All fuel tanks
10. Remove the 2 bolts from the front and rear fuel tank support straps.
- To install, tighten to 40 Nm (30 lb-ft).
11. Remove the front fuel tank support strap.
127L (33.5 gal) fuel tanks
12. NOTE: To assist in removing the center fuel tank support strap, the front of the fuel tank may need to be pushed up slightly to get the center fuel tank support strap to clear the fuel tank.
Lower the fuel tank slightly and rotate the center fuel tank support strap aside.
All fuel tanks
13. Rotate the rear fuel tank support strap aside.
14. Lower the fuel tank slightly. Disconnect the fuel pump module and fuel tank pressure sensor electrical connectors.
15. Remove the fuel tank from the vehicle.
127L (33.5 gal) fuel tanks
16. CAUTION: When installing a new fuel supply tube, fuel return tube or a fuel tank, it is essential that a new mastic patch be installed over both fuel tubes. If a new mastic patch is not installed correctly, fuel tube damage will occur.
NOTE: Clean the fuel supply tube, fuel return tube and the fuel tank of any dirt and foreign material before installing the new mastic patch.
If installing a new fuel supply tube, fuel return tube or a fuel tank, install a new mastic patch over both fuel tubes. Position the mastic patch over the fuel tubes as shown. If the patch is installed too far inboard, it can interfere with installation of the fuel tank.
17. If installing a new center fuel tank support strap, remove the center fuel tank support strap from the vehicle.
All fuel tanks
18. If installing a new rear fuel tank support strap, remove the rear fuel tank support strap from the vehicle.
19. To install, reverse the removal procedure.