Removal Procedure

Fuel Tank Replacement

Removal Procedure

Tools Required
J 34730 Fuel Pressure Gauge




Caution: Provide additional support when a vehicle is on a hoist
- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a rip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.


Caution: Fuel Vapors can collect while servicing fuel system pads in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
- Use forced air ventilation such as a fan set outside of the trunk.
- Plug or cap any fuel system openings in order to reduce fuel vapor formation.
- Clean up any spilled fuel immediately.
- Avoid sparks and any source of ignition.
- Use signs to alert others in the work area that fuel system work is in process.

Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
- The fuel pipe connections
- The hose connections
- The areas surrounding the connections

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Release Procedure. Fuel Pressure Release
2. Drain the fuel tank (5). Refer to Fuel Tank Draining Procedure. Service and Repair
3. Raise the vehicle.
4. Remove the exhaust system.




5. Remove the fuel tank filler pipe (2) from the grommet (1).
6. Remove the wheel house filler pipe opening cover.





7. Loosen the fuel tank filler pipe hose clamp (2) from the fuel tank filler pipe (1).




8. Disconnect the fuel feed (5), fuel return (6) quick connect pipes near the fuel filter.
9. Disconnect the [1][2]EVAP pipes (1), (2) at the evaporative emission canister.




10. Remove the rear tie rod ends.
11. Remove the rear suspension support assembly bolts and the lower suspension support assembly.
12. Remove the fuel tank bolts (4) from the fuel tank straps (2).
13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.