Fuel Tank: Service and Repair

Fuel Tank Replacement

1. Drain the fuel tank. Service and Repair

2. Reinstall the fuel tank unit without connecting the fuel tank unit 4P connector and the quick-connect fitting. Fuel Tank Unit Removal and Installation

3. Remove the fuel fill pipe cover. Service and Repair

4. Disconnect the quick-connect fittings (A) Fuel Line/Quick-Connect Fitting Removal (and on all models except PZEV, disconnect the fuel fill tube (B) from the fuel fill pipe).
Slide back the clamps, then twist the hose as you pull to avoid damaging them.

5. Raise the vehicle on a lift.

All models except PZEV





PZEV model





6. Disconnect the hose (A) from the EVAP canister.

7. Remove the hose (B) from the clamp (C).
NOTE: Be careful not to damage the hose.

8. Remove the exhaust pipe. Service and Repair

9. Remove the right side middle floor undercover. Service and Repair






10. Remove the fuel tank protector (A).

11. Remove the right parking brake cable mounting bolts. Service and Repair

12. Place a jack or other support under the fuel tank (B).

13. Remove the strap bolts (C) and the straps (D).

14. Remove the fuel tank.

15. Install the parts in the reverse order of removal.
NOTE:

- New fuel tanks have a ring pull (E) at the fuel vapor hose connector (F). When you connect the hose and confirm that the connection is secure, remove the ring pull by pulling it down.

- Before connecting the fuel fill pipe and the quick-connect fitting, check for dirt, and clean them if needed, taking care not to damage the fuel fill pipe and other parts.

- When installing the fuel tank protector, make sure insert direction of the clip (G).