Fuel Tank Replacement (Long Wheel Base)
Fuel Tank Replacement (Long Wheel Base)
Removal Procedure
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 Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027)).
2. Drain the fuel tank. Refer to Fuel Tank Draining (Service and Repair).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
4. Disconnect the fuel feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Disconnect the evaporative emission (EVAP) pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
6. Disconnect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting from the fuel tank vapor recirculation hose (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
7. Loosen the fuel fill hose clamp at the fuel tank.
8. Remove the fuel fill hose from the fuel tank (4).
9. Disconnect the fuel tank wiring harness (1) electrical connector from the body wiring harness pass-through.
10. Center an adjustable jack under the fuel tank.
11. Remove the fuel tank shield.
12. Remove the fuel tank strap bolts (2), and reposition the fuel tank straps (1).
13. With the aid of an assistant, support and lower the fuel tank (3).
14. Remove the fuel tank from the adjustable jack and place on a suitable work surface.
15. If the fuel tank is not being replaced, proceed to the installation procedure.
Disassembly Procedure
1. Remove the EVAP canister (2). Refer to Evaporative Emission Canister Replacement (Long Wheel Base) (Evaporative Emission Canister Replacement (Long Wheel Base))Evaporative Emission Canister Replacement (Short Wheel Base) (Evaporative Emission Canister Replacement (Short Wheel Base)).
2. Remove the EVAP canister vent valve (3). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement (Short Wheel Base) (Evaporative Emission Canister Vent Solenoid Valve Replacement (Short Wheel Base))Evaporative Emission Canister Vent Solenoid Valve Replacement (Long Wheel Base) (Evaporative Emission Canister Vent Solenoid Valve Replacement (Long Wheel Base)).
3. Remove the fuel tank module (4). Refer to Fuel Tank Module Replacement (Short Wheel Base) (Fuel Tank Module Replacement (Short Wheel Base))Fuel Tank Module Replacement (Long Wheel Base) (Fuel Tank Module Replacement (Long Wheel Base)).
4. Remove the fuel feed pipe (1) from the fuel tank pipe clips.
5. Remove the EVAP purge pipe (6) from the fuel tank pipe clip.
Assembly Procedure
1. Install the EVAP purge pipe (6) into the fuel tank clip.
2. Install the fuel feed pipe (1) into the fuel tank pipe clips.
3. Install the fuel tank module (4). Refer to Fuel Tank Module Replacement (Short Wheel Base) (Fuel Tank Module Replacement (Short Wheel Base))Fuel Tank Module Replacement (Long Wheel Base) (Fuel Tank Module Replacement (Long Wheel Base)).
4. Install the EVAP canister vent valve (3). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement (Short Wheel Base) (Evaporative Emission Canister Vent Solenoid Valve Replacement (Short Wheel Base))Evaporative Emission Canister Vent Solenoid Valve Replacement (Long Wheel Base) (Evaporative Emission Canister Vent Solenoid Valve Replacement (Long Wheel Base)).
5. Install the EVAP canister (2). Refer to Evaporative Emission Canister Replacement (Long Wheel Base) (Evaporative Emission Canister Replacement (Long Wheel Base))Evaporative Emission Canister Replacement (Short Wheel Base) (Evaporative Emission Canister Replacement (Short Wheel Base)).
Installation Procedure
1. Remove the fuel tank from the work surface and place on the adjustable jack.
2. Support and install the fuel tank.
Notice: Refer to Fastener Notice (Fastener Notice).
3. Position the fuel tank straps (1) and install the strap bolts (2).
Tighten the bolts to 47 N.m (35 lb ft).
4. Remove the adjustable jack.
5. Install the fuel tank shield.
6. Connect the fuel tank wiring harness (1) electrical connector to the body wiring harness pass-through.
7. Install the fuel fill hose to the fuel tank (4).
8. Tighten the fuel fill hose clamp at the fuel tank.
Tighten the clamp to 2.5 N.m (22 lb in).
9. Connect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting to the fuel tank vapor recirculation hose (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
10. Connect the EVAP pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
11. Connect the fuel feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
12. Lower the vehicle.
13. Add fuel to the fuel tank.
14. Install the fuel fill cap.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
16. Inspect for fuel leaks using the following procedure:
1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect the fuel system for fuel leaks.
17. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (Service and Repair).