Removal and Replacement
Fuel Tank
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.
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: 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: 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: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the muffler and tail pipe.
3. Drain the fuel tank.
All-Wheel Drive (AWD) vehicles
4. Remove the driveshaft.
All vehicles
5. Remove the Evaporative Emission (EVAP) canister.
6. NOTE: Some residual fuel may remain in the fuel tank filler pipe after draining the fuel tank. Carefully drain any residual fuel into a suitable container.
Release the clamp and remove the fuel tank filler pipe hose from the fuel tank.
- To install, tighten to 3 Nm (27 lb-in).
7. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling.
8. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling.
9. Position the Powertrain Lift under the fuel tank.
10. Loosen the 2 rear fuel tank strap bolts.
- Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the Appendix.
- To install, use a torque adapter and tighten to 35 Nm (26 lb-ft).
11. Remove the 2 front fuel tank strap bolts.
- To install, tighten to 35 Nm (26 lb-ft).
12. NOTE: Do not bend or distort the fuel tank straps.
Release the 2 straps from the fuel tank and carefully position aside.
13. Partially lower the fuel tank enough to allow access to the fuel tank wire to the main body wiring harness electrical connector.
14. Release the 2 wire harness retainers and disconnect the fuel tank wire to the main body wire harness electrical connector.
15. Release the fresh air hose vent cap and pin-type retainer from the body.
16. Carefully lower and remove the fuel tank from the vehicle.
17. To install, reverse the removal procedure.