Fuel Tank Replacement
Removal Procedure1. Relieve the fuel system pressure. Refer to Fuel Pressure Release.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise and suitably support the vehicle.
4. Remove the four bolts and the rear crossmember from the underbody.
5. Disconnect the fuel level sensor (fuel gauge sending unit) electrical connector (2).
6. Disconnect the fuel pump electrical connector (1).
7. Disconnect the fuel tank pressure sensor electrical connector (3).
8. Remove the end bolt from the fuel feed inlet hose to the fuel filter.
9. Disconnect the fuel feed inlet hose from the fuel filter.
10. Loosen the clamp from the fuel breather hose and the fuel tank.
11. Disconnect the fuel breather hose (2) from the fuel tank.
12. Loosen the clamp from the fuel filler neck and the fuel tank.
13. Disconnect the fuel filler neck (1) from the fuel tank.
14. Loosen the clamp and disconnect the fuel return hose (4) from the fuel return pipe.
15. Loosen the clamp and disconnect the fuel vapor hose (3) from the fuel vapor pipe.
16. Remove the five bolts (3) and the fuel tank protector (4) from the fuel tank.
17. Support the fuel tank (2) while lowering the fuel tank from the vehicle.
18. Remove the fuel tank (1) from the vehicle.
Installation Procedure
1. Install the fuel tank assembly (1) to the vehicle underbody.
2. Install the fuel tank protector and secure with the five bolts (3). Tighten mounting bolts to 35 Nm (26 lb ft).
3. Connect the fuel vapor hose (3) to the fuel vapor pipe.
4. Secure the fuel vapor hose with one clamp.
5. Connect the fuel return hose (4) to the fuel return pipe.
6. Secure the fuel return hose with one clamp.
7. Install the fuel filter neck (1) to the fuel tank.
8. Secure the fuel filler neck with one clamp.
9. Connect the fuel breather hose (2) to the fuel tank.
10. Secure the fuel breather hose with one clamp.
11. Connect the fuel feed inlet hose to the fuel filter.
12. Secure the fuel feed inlet hose with one bolt and tighten to 35 Nm (26 lb ft).
13. Connect the fuel level sensor (fuel gauge sending unit) electrical connector (2).
14. Connect the fuel pump electrical connector (1).
15. Connect the fuel tank pressure sensor electrical connector (3).
16. Install the rear crossmember to the vehicle underbody.
17. Secure the rear crossmember with four bolts and tighten the rear crossmember bolts to 70 Nm (51 lb ft).
18. Lower the vehicle.
19. Refill the fuel tank.
20. Inspect for fuel leaks.
21. Connect the negative battery cable and tighten the terminal retainer bolt to 15 Nm (11 lb ft).
22. Turn ON the ignition for three seconds.
23. Turn OFF the ignition.
24. Check for any fuel leaks and repair as necessary.