Fuel Tank Replacement

REMOVAL

CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAME IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE.

1. Ensure that fuel level in tank is less than 1/4 full. If necessary, drain fuel tank to at least this level. (Refer to "Fuel Tank Draining" procedure.)

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. 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.

2. Position vehicle on hoist.

CAUTION: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONGER PERIODS OF TIME AFTER THE ENGINE IS SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM.

3. Relieve fuel system pressure. (Refer to "Fuel System Pressure Relief" procedure.)

CAUTION: ANY TIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.

4. Disconnect negative battery cable.
5. Raise vehicle on hoist.




6. Remove rubber exhaust hangers on order to allow exhaust system to drop slightly.
7. Remove propeller shaft guard. IF EQUIPPED.
8. Remove propeller shaft. IF EQUIPPED.

NOTE: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.




9. Disconnect EVAP canister vent and fresh air hoses.
9.1 Grasping both sides of the quick-connect fitting. Twist the female connector 1/4 turn in each direction in order to loosen dirt within the quick-connect fitting.
9.2 Blow any dirt out of the quick-connect fitting using compressed air.
9.3 Squeeze the plastic retainer release tabs.
9.4 Pull the connection apart.
9.5 Inspect both ends of the quick-connect fitting for dirt and burrs.




10. Remove fuel fuller pipe, EVAP vent hose, and fresh air hose from fuel tank.

CAUTION: WHENEVER FUEL LINES ARE REMOVED, PLACE FUEL IN AN APPROVED CONTAINER. CONTAINER OPENING MUST BE A MINIMUM OF 300 MM (12 IN.) DIAMETER TO ADEQUATELY CATCH FUEL.

11. Disconnect fuel supply line from fuel filter.
12. Disconnect fuel tank ground strap fastener.
13. Disconnect fuel tank electrical connector.

NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.




14. Support fuel tank.
15. Remove fuel tank strap bolts.
16. Lower fuel tank from underbody of vehicle.

DISASSEMBLY




1. Place fuel tank in a suitable work area.
2. Remove primary fuel pump module from fuel tank.




3. Remove secondary fuel pump module from fuel tank.
4. Remove fuel and EVAP lines from fuel tank.
5. Remove electrical harness from fuel tank.

ASSEMBLY

IMPORTANT: Always replace fuel pump module-to-tank seal (H-ring) whenever assembly is removed.

1. Install primary fuel pump module into fuel tank.




2. Install new fuel filter onto fuel tank.

Torque:
Fuel Filter Bracket Bolt: 2 N.m (18 in-lbs)

3. Install fuel and EVAP lines onto fuel tank.
3.1 Apply a few drops of clean engine oil to the male fuel pipe end.
3.2 Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to snap into place.
3.3 Pull both sides of quick-connect in order to make sure connection is secure, once installed.

INSTALLATION




1. Install fuel tank heat shield and fuel tank assembly into vehicle.




2. Install fuel tank straps and tighten bolts

Torque:
Fuel Tank Strap-to-Body Bolts: 25 N.m (18 ft-lbs)




3. Install fuel filler pipe, EVAP vent, and fresh air hoses to fuel tank.
4. Install fuel tank ground strap fastener (by fuel filter).

Torque:
Ground Strap-to-Body Bolt: 8 N.m (71 in-lbs)




5. Connect EVAP canister vent and fresh air hoses to fuel tank hoses.
6. IF EQUIPPED, install propeller shaft.
7. IF EQUIPPED, install propeller shaft guard.




8. Install rubber exhaust hangers.
9. Lower vehicle from hoist.
10. Fill fuel tank with gasoline.
11. Connect the negative battery cable.

Torque:
Battery Terminal Bolt: 17 N.m (13 ft-lbs)

12. Prime fuel system.
12.1 Cycle ignition On for 5 seconds and then Off for 10 seconds.
12.2 Repeat previous step twice.
12.3 Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
12.4 If engine does not start, repeat steps 12.1-12.3.