Fuel Tank: Service and Repair

FUEL TANK

Part 1:

Part 2:

Exploded View

Special Tool(s):

Special Tool(s)

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Release the fuel system pressure.
4. Remove the driveshaft.







5. Disconnect the fuel filler hose from the fuel filler intermediate pipe.







6. Use the special tool and a suitable tanker and siphon the fuel through the fuel filler hose.
7. Remove the fuel tank skid plate, if equipped.







8. Disconnect the safety clip from the fuel supply tube.







9. Install the special tool and press it into the fitting.







10. NOTE: To install, lubricate the fuel fitting with clean engine oil.

Separate the fittings.
- To install, align the fuel line fitting and press together until a click is heard.
- Pull on the fitting to make sure it is fully engaged, then install the safety clip.

11. Disconnect the vapor tube connector.







12. Use a suitable jack to support the fuel tank.
13. Remove the nut from the front fuel tank support strap.
- To install, tighten to 55 Nm (41 lb-ft).

14. Remove the bolt from the rear fuel tank support strap.
- To install, tighten to 55 Nm (41 lb-ft).

15. Disconnect the fuel vapor hose from the fuel vapor vent valve.
- To install, lightly lube with clean engine oil.

16. Disconnect the fuel filler pipe hose from the fuel vapor tee.
- To install, lightly lube with clean engine oil.

17. Disconnect the fuel pump electrical connector.
18. Disconnect the vapor tube connector.
19. Remove the fuel tank.
20. To install, reverse the removal procedure.