Fuel Tank Assembly Replacement Procedure

1. Depressurize the fuel system following the instructions in the Service Manual Section 5.1.3.

2. Remove the trunk carpet and front liner.

3. Disconnect the battery negative cable.

4. Remove the left side rear lamp interior finisher, trunk seal retainer, and left side trunk liner.

5. Drain the fuel tank.

WARNING:
Use only approved equipment to drain the fuel tank. Observe all safety precautions when working on the fuel system.

6. Raise the vehicle. Use tool JD 203 to disconnect the fuel tank supply and return lines. Plug all open fuel lines to prevent leakage and contamination.

7. Disconnect the fuel filler drain hose under the vehicle.

8. Lower the vehicle. Remove the CD player and amplifier (where applicable) from the fuel tank evaporative flange area and set aside.

9. Disconnect the vehicle harness from the evaporative loss flange and disconnect the fuel tank sender unit connectors.





10. Remove the tie straps securing the filler drain hose to the filler neck. Remove the filler drain hose spring clamp (Illustration 1) and remove the drain hose from the body grommet

11. Disconnect the vapor line from the fuel tank using tool JD 203.

12. Remove the fuel filler cap to access the filler neck seal spring.





13. Remove the filler neck spring from around the filler neck seal and pull the seal up, free of the filler neck (Illustration 2).





14. Loosen the fuel tank retaining strap tensioning bolts at the lower brackets (Illustration 3). Remove the bracket retaining bolts. Leave the brackets attached to the retaining straps.

15. Tape the retaining straps to the bulkhead clear of the tank.

16. Support the trunk lid and remove the left side trunk lid support strut retaining clip. Detach the strut from the trunk lid.

17. Remove the fuel tank and drain any remaining fuel from the tank.

WARNING:
Observe all safety precautions when working on the fuel system

18. Install the replacement tank by reversing the steps above.

19. Transfer the drained fuel to the newly installed tank.

20. Connect the battery and check the fuel system for leaks and proper operation.

21. Reset the clock to the correct time.