Fuel Tank: Service and Repair

Fuel Tank Replacement

Removal Procedure

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Drain the fuel tank.
2. Relieve the fuel system pressure.
3. Remove the exhaust system.
4. Remove the propeller shaft.






5. Disconnect the filler hose (1) from the fuel tank.
6. Disconnect the filler vent tube (2) from the evaporative emission (EVAP) hose.






7. Refer to Plastic Collar Quick Connect Fitting Service in order to disconnect the following from the chassis bundle:
- The fuel feed hose.
- The fuel return hose.
- The fuel EVAP hose.






8. Disconnect the fuel tank electrical connector.






9. Disconnect the EVAP hoses from the EVAP canister.
10. Pull outward on the retainer tab in order to disengage the retainer from the chassis.
11. Disconnect the electrical connector from the EVAP canister.






12. Raise the lower control arms using a suitable screw jack (3) in order to remove the load from the lower shock bolts (2).
13. Remove the lower shock bolts (2).
14. Remove the screw jack (3).






15. Position the screw jack under the rear frame near the adjuster tie bar, in order to support the front of the rear frame.
16. Remove the 2 front bolts from the rear frame.






Important: Use care not to over extend the rear brake hoses.

17. Lower the screw jack until there is approximately 50 mm (2 in) (a) between the front mounting surface of the rear frame and the chassis.
- This will allow clearance to access the fuel tank strap bolts.






18. Remove the fuel tank strap bolts.
19. Position the fuel tank straps downward around the rear frame.
20. Carefully bend the fuel tank straps ONLY enough to allow the fuel tank to be removed.

Important: Ensure the following are free from the surrounding components while lowering the fuel tank:
- The fuel tank wiring harness.
- The EVAP wiring harness.
- The EVAP hoses at the EVAP.
- The fuel/EVAP hoses at the chassis pipes.

21. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
22. Remove the following components if replacing just the fuel tank:
- The primary fuel tank module.
- The secondary fuel tank module.
- The fuel tank pressure sensor.

Installation Procedure

1. Install the following components if fuel tank replacement was necessary:
- The primary fuel tank module.
- The secondary fuel tank module.
- The fuel tank pressure sensor.
2. Pressure test the fuel tank.

Important: Ensure the following are properly routed while raising the fuel tank:
- The fuel tank wiring harness.
- The EVAP wiring harness.
- The EVAP hoses at the EVAP.
- The fuel/EVAP hoses at the chassis pipes.






3. With the aid of an assistant, carefully raise the fuel tank to the vehicle, aligning the filler neck with the filler hose.

Important: Ensure the fuel tank straps are not pressed into the fuel tank.

4. Carefully bend the fuel tank straps back to their original form.
5. Position the fuel tank straps around the rear frame and upward into position, aligning the holes in the straps with the threaded holes in the chassis.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the fuel tank strap bolts. Tighten the fuel tank strap bolts to 50 Nm (37 lb ft).






7. Connect the filler hose (1) to the fuel tank. Tighten the fuel filler tube hose clamp (3) to 3.5 Nm (31 lb in).
8. Connect the filler vent tube (2) to the EVAP hose.






9. Connect the EVAP hoses to the EVAP canister.
10. Insert the retainer into the chassis and press inward on the tab to engage.
11. Connect the electrical connector to the EVAP canister.






12. Connect the fuel tank electrical connector.






13. Refer to Plastic Collar Quick Connect Fitting Service in order to connect the following to the chassis bundle:
- The fuel feed hose.
- The fuel return hose.
- The fuel EVAP hose






14. Raise the rear frame using the screw jack.
15. Install the 2 front bolts to the rear frame. Tighten the rear frame bolts to 200 Nm (148 lb ft).
16. Remove the screw jack.






17. Position the screw jack (3) under the lower control arm in order to raise the lower control arms (2).
18. Install the lower shock bolts (2). Tighten the lower shock bolts to 90 Nm (66 lb ft).
19. Remove the screw jack (3).
20. Install the propeller shaft.
21. Install the exhaust system.
22. Refill the fuel tank.
23. Inspect for fuel leaks.