Removal and Replacement
Fuel Tank
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.
WARNING: 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.
WARNING: 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.
WARNING: 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.
WARNING: 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 (177 lb-in).
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 (177 lb-in).
All fuel tanks
5. Disconnect the fuel tank filler pipe vent tube-to-Fuel Tank Pressure (FTP) sensor and vapor tube assembly quick connect coupling in the rear of the fuel tank.
6. Disconnect the FTP (Fuel Tank Pressure) sensor and vapor tube assembly-to-Evaporative Emission (EVAP) canister quick connect coupling in the front of the fuel tank.
7. Disconnect the fuel tank fuel supply tube-to-front fuel supply tube quick connect coupling.
8. Remove the 4 sway bar bracket nuts and let the sway bar hang down.
- To install, tighten to 48 Nm (35 lb-ft).
9. NOTICE: Do not support the fuel tank directly beneath the Fuel Pump (FP) mounting area. Damage to the FP (Fuel Pump) assembly can occur.
Position a jack under the fuel tank.
127L (33.5 gal) fuel tank
10. Remove the center fuel tank support strap bolt.
- To install, tighten to 40 Nm (30 lb-ft).
All fuel tanks
11. Remove the 2 bolts from the front and rear fuel tank support straps.
- To install, tighten to 40 Nm (30 lb-ft).
12. Remove the front fuel tank support strap.
127L (33.5 gal) fuel tanks
13. 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
14. Rotate the rear fuel tank support strap aside.
15. Lower the fuel tank slightly. Disconnect the fuel pump module and fuel tank pressure sensor electrical connectors.
16. Remove the fuel tank from the vehicle.
127L (33.5 gal) fuel tanks
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.