Fuel Tank Removal and Installation

REMOVAL
1. Release fuel system pressure. Refer to Fuel Pressure Release Procedure in this section.
2. Drain the fuel tank before removing it from the vehicle. Refer to Draining Fuel Tank.
3. Disconnect positive battery cable at the PDC.

Fig. 11 Fuel Tank Closeout Panel:

The trunk will have to have an closeout panel cut into it for servicing the fuel tank (Fig. 11). Refer to the Body section.

4. Remove spare tire. Remove spare tire tool kit.
5. Remove trunk trim panels from trunk area, refer to the Body section.
6. Remove the radio amplifier and bracket.
7. Remove trunk carpet, refer to the Body section.
8. Cut closeout panel hole for fuel tank, refer to the Body section.

Fig. 13 Fuel Filter Neck Removal/Installation:

9. Remove Fuel Filler neck mounting screws (Fig. 13).
10. Reach inside and disconnect the filler tube at the fuel tank.
11. Remove the rubber vapor recirculation line at the fuel filler tube.
12. Disconnect the EVAP canister supply line at the ORVR control valve.
13. Reach inside and remove the two fuel tank attaching bolts.
14. Slide the fuel tank rearward and disconnect the fuel line at the fuel pump module and the electrical connector. To absorb any fuel still in the tubes, wrap shop towels around ends of fuel supply line.
15. Remove fuel tank from vehicle.

INSTALLATION
1. Install fuel tank half way through closeout opening.
2. Connect fuel pump module electrical connector to fuel pump module.
3. Connect the EVAP canister supply line at the ORVR control valve.
4. Connect fuel line to the fuel pump module. Refer to Quick-Connect Fittings in the Fuel Delivery Section of this group.
5. Slide tank forward.
6. Reach inside and connect the filler tube at the fuel tank. Tighten clamp.
7. Install the rubber vapor recirculation line to the fuel filler tube.
8. Position fuel filler neck in opening in body panel. Install and tighten mounting screws (Fig. 13).
9. Reach inside and install the two fuel tank attaching bolts. Tighten to 20 Nm (177 in. lbs.) torque.
10. Connect positive battery cable at the PDC.
11. Fill fuel tank.
12. Use the DRB Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
13. Install closeout panel in trunk. Refer to the Body section.
14. Install trunk carpet, refer to the Body section.
15. Install the amplifier and bracket.
16. Install trunk trim panels into trunk area, refer to the Body section.
17. Install spare tire tool kit. Install spare tire.
18. Clean trunk area.