2-Door Models

WARNING: Do not smoke, 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.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL
1. Perform fuel pressure release procedure.
2. Drain the fuel tank.
3. Disconnect the battery ground cable.
4. Remove the rear seat cushion and cover.
5. Remove the LH quarter trim panel.

Luggage Compartment Floor Cover:

6. Use a suitable tool to remove the three luggage compartment floor cover hold-down pins.
7. Fold the luggage compartment floor cover forward until the fuel pump assembly access plate is uncovered.
8. Remove the fuel pump assembly access plate screws.
9. Lift the fuel pump assembly access plate and disconnect the fuel pump assembly electrical connector.
10. Disconnect the fuel supply line from the fuel level sensor.
11. Disconnect the fuel return line from the top of the fuel tank.

Filler Cover:

12. Remove the six inner rear floor filler cover bolts and the two inner rear floor filler cover nuts.
13. Remove the inner rear floor filler cover.

Filler Pipe Hose:

14. Loosen the hose clamps and disconnect the fuel tank to filler pipe hose and the three evaporative emission hoses from the fuel tank.
15. Disconnect the overflow hose from the fitting on the fuel tank.
16. Raise and support the vehicle.

Vapor Hose:

17. Squeeze the hose clamp and disconnect the vapor hose from the fuel evaporation pipe.

NOTE: The fuel tank bolts are coated with a special thread-lock material. Therefore, they must be replaced with new bolts whenever removed.

18. Remove the four fuel tank bolts and discard.
19. Move the fuel tank toward the left and remove it from under the vehicle.

INSTALLATION

1. Slide the fuel tank into position from the LH side of the vehicle.
2. Install the four new fuel tank bolts. Tighten the four fuel tank bolts to 26-34 Nm (20-25 lb ft).
3. Connect the vapor hose to the fuel evaporation pipe.
4. Lower the vehicle.
5. Connect the three evaporative emission hoses to the fittings on the fuel tank.
6. Connect the overflow hose to the fitting on the fuel tank.
7. Connect the fuel tank to filler pipe hose to the fitting on the fuel tank.
8. Connect the fuel return line to the fitting on the top of the fuel tank.
9. Connect the fuel supply line to the fitting on the fuel level sensor.
10. Add fuel to the fuel tank.
11. Perform a visual inspection for leaks and repair as necessary.
12. Connect the battery ground cable.
13. Connect the fuel pump assembly electrical connector and start the engine. Visually inspect for leaks at all locations, and repair leaks as necessary.
14. Position the inner rear floor filler cover and install the six inner rear floor filler cover bolts and the two inner rear floor filler cover nuts.
15. Tighten the six inner rear floor filler cover bolts and the two inner rear floor filler cover nuts to 10-23 Nm (8-16 lb ft).
16. Position the fuel pump assembly access plate.
17. Install the fuel pump assembly access plate screws.
18. Position the luggage compartment floor cover and install the three luggage compartment floor cover hold-down pins.
19. Install the LH quarter trim panel.
20. Install the rear seat cushion and cover.