Removal and Replacement

Fuel Tank Replacement

Special Tools

EN-48536 - Engine Support Tool (Engine Lower 65 MM Kit)

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Warning:
Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.


1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Drain the fuel tank. Refer to Fuel Tank Draining Procedures.

3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.

4. Remove the exhaust system. Refer to Exhaust System Replacement (V6) Service and RepairExhaust System Replacement (V8) Service and Repair.

5. Remove the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) Propeller Shaft Replacement (Except 4L60).

6. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation Service and Repair.





7. Disconnect the evaporative emission (EVAP) hose (1), by squeezing both sides of the hose (as indicated in the illustration) and pulling it toward the rear of the vehicle.





8. Release the worm drive hose clamp (1) and remove the filler tube (2).





9. Disconnect the fuel feed pipe (1) and EVAP emission pipe (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





10. Disconnect the fuel tank electrical connector (1).





11. Support the rear frame assembly using a suitable tool.





12. Remove the rear frame to chassis retaining bolts (1) and (2) and discard.





13. Support the rear frame using the frame support tool EN-48536 - Engine Support Tool (Engine Lower 65 MM Kit)(1). Repeat for the opposite side.





Note:
When lowering the rear frame use care not to over extend the rear brake hoses.

14. Support the rear frame using the frame support tool EN-48536 - Engine Support Tool (Engine Lower 65 MM Kit) (1). Repeat for the opposite side.

15. Lower the rear frame approximately 50 millimeters (2 in) (A) at the rear mounting surface between the rear frame and the chassis.

16. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement Fuel Tank Heat Shield Replacement.

17. Disconnect the park brake rear cables from the park brake front cable equalizer bracket assembly. Refer to Parking Brake Front Cable Replacement (9C1 - Front) Parking Brake Front Cable Replacement (9C1 - Front)Parking Brake Front Cable Replacement (9C3) Parking Brake Front Cable Replacement (9C3)Parking Brake Front Cable Replacement (9C1 - Rear) Parking Brake Front Cable Replacement (9C1 - Rear).





18. Disconnect the EVAP emission pipe (2) from the EVAP emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





19. With the aid of an assistant support the fuel tank

20. Remove the fuel tank strap to chassis retaining bolts (1).

21. Remove the fuel tank straps.

Note:
Do not damage the fuel tank wiring harness or fuel tank hoses.

22. With the aid of an assistant, remove the fuel tank from the vehicle.

23. Remove the following components from the fuel tank if the fuel tank is to be replaced.

* The primary fuel tank module-Refer to Primary Fuel Tank Module Replacement Primary Fuel Tank Module Replacement.

* The secondary fuel tank module-Refer to Secondary Fuel Tank Module Replacement Secondary Fuel Tank Module Replacement.

Installation Procedure

1. Install the following components to the fuel tank if the fuel tank was replaced.

* The primary fuel tank module - Refer to Primary Fuel Tank Module Replacement Primary Fuel Tank Module Replacement.

* The secondary fuel tank module - Refer to Secondary Fuel Tank Module Replacement Secondary Fuel Tank Module Replacement.

Note:
Make sure the following are correctly:

* The fuel tank wiring harness.

* The fuel tank pipes.





2. With the aid of an assistant, install the fuel tank to the vehicle.

3. With the aid of an assistant support the fuel tank and install the fuel tank straps.

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the fuel tank strap retaining bolts (1).

Tighten the bolts to 30 Nm (22 lb ft).





5. Connect the EVAP emission pipe (2) to the EVAP emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

6. Install the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement Fuel Tank Heat Shield Replacement.





7. Raise the rear frame assembly using suitable tool.





8. Remove the frame support tool EN-48536 - Engine Support Tool (Engine Lower 65 MM Kit) (1) from the rear frame. Repeat for the opposite side.





9. Remove the frame support tool EN-48536 - Engine Support Tool (Engine Lower 65 MM Kit) (1) from the rear frame. Repeat for the opposite side.

10. Using a suitable tool clean the threaded holes in the rear chassis.





Note:
Rear frame retaining bolts must not to be fully tightened at this stage.

11. Install the NEW rear frame to chassis retaining bolts (1 and 2).

Do not fully tighten at this stage.

12. After retaining bolts (1 and 2) are installed tighten to.

* First Pass: Tighten the bolts to 65 Nm (48 lb ft)

* Final Pass: Tighten the bolts a further 125 degrees.





13. Remove the support tool.





14. Connect the fuel tank electrical connector (1).





15. Connect the fuel feed pipe (1) and the EVAP pipe (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





Note:
Listen for an audible click to confirm correct installation of the EVAP emission hose (1).

16. Install the EVAP emission hose (1).





17. Connect the filler hose (2) to the fuel tank.

Tighten the fuel filler tube hose clamp (1) to 4 Nm (35 lb in).

18. Connect the park brake rear cables to the park brake front cable equalizer bracket assembly. Refer to Parking Brake Front Cable Replacement (9C1 - Front) Parking Brake Front Cable Replacement (9C1 - Front)Parking Brake Front Cable Replacement (9C3) Parking Brake Front Cable Replacement (9C3)Parking Brake Front Cable Replacement (9C1 - Rear) Parking Brake Front Cable Replacement (9C1 - Rear).

19. Install the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) Propeller Shaft Replacement (Except 4L60).

20. Install the exhaust system. Refer to Exhaust System Replacement (V6) Service and RepairExhaust System Replacement (V8) Service and Repair.

21. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation Service and Repair.

22. Refill the fuel tank.

23. Inspect for fuel leaks.