Fuel Tank Replacement

REMOVAL

1. Release fuel system pressure. Refer to Fuel Pressure Release Procedure.
Service and Repair

2. Disconnect positive battery cable at the PDC.

3. Drain the fuel tank before removing it from the vehicle. Refer to Draining Fuel Tank.
Fuel Tank Draining Procedure

Fuel Tank Closeout Panel:

The trunk will have to have an closeout panel cut into it for servicing the fuel tank.

4. Remove spare tire. Remove spare tire tool kit.

5. Remove trunk trim panels from trunk area.

6. Remove the radio amplifier and bracket.

7. Remove trunk carpet.

8. Cut closeout panel hole for fuel tank.

Fuel Filler Neck Removal/Installation:

9. Remove Fuel Filler neck mounting screws.

10. Reach inside and disconnect the filler tube at the fuel tank.

11. Reach inside and remove the two fuel tank attaching bolts.

12. Slide the fuel tank rearward and disconnect the fuel line at the pressure regulation remove the rollover valve vent tube, and the electrical connector. To absorb any fuel still in the tubes, wrap shop towels around ends of fuel supply and vapor tubes.

13. Remove the fill vent tube from the fuel pump module.

14. Remove fuel tank from vehicle.

INSTALLATION

1. In stall fuel tank half way through closeout opening.

2. Connect fuel pump module electrical connector to fuel pump module.

3. Connect the fill vent tube to the fuel pump module.

4. Connect fuel line to the pressure regulator. Refer to Quick-Connect Fittings.
Service and Repair

5. Connect rollover vent tube.

6. Slide tank forward.

7. Reach inside and connect the filler tube at the fuel tank. Tighten clamp.

8. Position fuel filler neck in opening in body panel. Install and tighten mounting screws.

9. Reach inside and install the two fuel tank attaching bolts. Tighten to 20 Nm (177 in. lbs.) torque.

10. Connect positive battery cable at the PDC.

11. Fill fuel tank.

CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position.

12. Use the DRB Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

13. Install closeout panel in trunk.

14. Install trunk carpet.

15. Install the amplifier and bracket.

16. Install trunk trim panels into trunk area.

17. Install spare tire tool kit. Install spare tire.

18. Clean trunk area.