Fuel Tank Replacement

FUEL TANK REPLACEMENT

WARNING: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

PRELIMINARY STEPS
- Relieve fuel system pressure. Refer to Fuel Pressure Release/Service and Repair. Service and Repair
- Drain fuel tank.
- Raise and suitably support vehicle.













REMOVE OR DISCONNECT
1. Four bolts and rear crossmember from underbody.
2. Fuel level sensor (fuel gage sending unit) and fuel pump electrical connectors.
3. Fuel Tank Pressure Sensor electrical connector (vehicles with Enhanced EVAP only).
4. One bolt and fuel feed inlet hose from fuel filter.
5. One clamp and fuel breather hose from fuel tank.
6. One clamp and fuel filler neck from fuel tank.
7. One clamp and fuel return hose from fuel return pipe.
7. One clamp and fuel vapor hose from fuel vapor pipe.
9. Five bolts and fuel tank protector and fuel tank from vehicle.

- Support fuel tank while lowering from vehicle.

DISASSEMBLE
1. One bolt and fuel tank protector from fuel tank.
2. Five screws and fuel level sensor (fuel gage sending unit) from tank.
3. Six screws and fuel pump from fuel tank.
4. Two screws and Fuel Tank Pressure Sensor and hoses from tank.
5. Two clamps, two screws and fuel vapor separator and hoses from fuel tank.
6. Fuel tank inlet valve from fuel tank.

ASSEMBLE
1. Fuel tank inlet valve to fuel tank.
2. Fuel vapor separator and hoses to fuel tank; secure with two screws and two clamps.
3. Fuel Tank Pressure Sensor and hoses to fuel tank, secure with two screws.
4. Fuel pump to fuel tank; secure with six screws.
5. Fuel level sensor (fuel gage sending unit) to fuel tank; secure with five screws.
6. Fuel tank protector to fuel tank; secure with one bolt. Tighten fuel tank protector to fuel tank bolt to 25 Nm (18 lb. ft.).

INSTALL OR CONNECT

- Raise and support fuel tank protector and fuel tank.

1. Fuel tank protector and fuel tank to underbody; secure with five bolts. Tighten fuel tank protector and fuel tank mounting bolts to 35 Nm (26 lb. ft.).
2. Fuel vapor hose to fuel vapor pipe; secure with one clamp.
3. Fuel return hose to fuel return pipe; secure with one clamp.
4. Fuel filler neck to fuel tank; secure with one clamp.
5. Fuel breather hose to fuel tank; secure with one clamp.
6. Fuel feed inlet hose to fuel filter; secure with one bolt. Tighten fuel feed inlet hose-to-fuel filter bolt to 35 Nm (26 lb. ft.).
7. Fuel pump and fuel level sensor electrical connectors.
8. Rear crossmember to underbody; secure with four bolts. Tighten rear crossmember bolts to 70 Nm (51 lb. ft.).
- Lower vehicle.
- Refill fuel tank.
9. Negative (-) battery cable. Tighten negative (-) battery cable-to-negative (-) battery terminal retainer to 15 Nm (11 lb. ft.).

AFTER REPAIR INSPECTION
Turn ignition switch to "ON," and then back to "LOCK" to pressurize the fuel system. Check for any fuel leaks.