Fuel Tank Replacement (Seven Passenger)

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the frame brace.
4. Remove the fuel tank shield, if equipped.
5. Loosen the fuel hose clamp (1) at the fuel tank.
6. Separate the fuel hose (2) from the fuel tank.




7. Disconnect the fuel feed pipe (1) and evaporative emission (EVAP) pipe (2).
8. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.




9. With the aid of an assistant, support the fuel tank.
10. Remove the fuel tank strap bolts (1).

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions.

11. Remove the fuel tank straps (2).
12. Carefully lower the fuel tank.




13. Disconnect the fuel tank pressure sensor electrical connector (4).
14. Disconnect the EVAP vent valve electrical connector (9).
15. Disconnect the fuel tank module (3) electrical connector.
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.
18. If the fuel tank is not being replaced, go to the Installation Procedure.

DISASSEMBLY PROCEDURE




1. Remove the fuel feed pipe from the fuel module and retaining clip.




2. Remove the EVAP solenoid pipe (3) from the vent solenoid valve and the EVAP canister.
3. Remove the EVAP pipe assembly (2) from the fuel tank vent valves, the fuel module, and the EVAP canister.
4. Remove the EVAP canister purge pipe (1) from the EVAP canister and retaining clip.




5. Remove the EVAP vent valve (9).
6. Remove the fuel sender assembly (3) from the fuel tank.
7. Remove the EVAP canister (2).

ASSEMBLY PROCEDURE




1. Install the EVAP canister (2).
2. Install the fuel sender assembly (3) to the fuel tank.
3. Install the EVAP vent valve (9).




4. Install the EVAP canister purge pipe (1) to the EVAP canister and retaining clip.
5. Install the EVAP pipe assembly (2) to the fuel tank vent valves, the fuel module, and the EVAP canister.
6. Install the EVAP solenoid pipe (3) to the vent solenoid valve and the EVAP canister.




7. Install the fuel feed pipe to the fuel module and retaining clip.

INSTALLATION PROCEDURE




1. With the aid of an assistant, position and support the fuel tank.
2. Connect the fuel sender electrical connector (3).
3. Connect the fuel tank pressure sensor electrical connector (4).
4. Connect the EVAP vent valve electrical connector (9).




5. Install the fuel tank straps (2).
6. Install the fuel tank strap bolts (1).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the bolts to 32 N.m (24 lb ft).




7. Remove the caps from the fuel and EVAP pipes.
8. Connect the fuel feed pipe (1) and EVAP pipe (2).




9. Connect the fuel hose (2) to the fuel tank.

Tighten the clamp (1) to 2.5 N.m (22 lb in).

10. Lower the vehicle.
11. Refill the fuel tank.
12. Install the fuel fill cap.
13. Connect the negative battery cable.
14. Inspect for leaks.
1. Turn the ignition ON, with the engine OFF for 10 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.
15. Install the fuel tank shield, if equipped.
16. Install the frame brace.
17. Lower the vehicle.