4-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 four 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 pump assembly housing.
11. Disconnect the fuel return line from the top of the fuel tank.
12. Raise and support the vehicle.
13. Position a suitable jack under the fuel tank.

Filler Pipe Hose:

14. Loosen the two screw-type clamps and remove the fuel tank to filler pipe hose and the overflow hose.

Support Straps:

15. Remove the two fuel tank support strap bolts and the fuel tank support straps. Unhinge the opposite fuel tank support strap ends and remove the fuel tank support straps from the vehicle.
16. Push the brake hose clip through the bracket on the fuel tank and position the front parking brake cable and conduit out of the way.
17. Ensure that the fuel tank to filler pipe hose and the front parking brake cable and conduit are positioned out of the way to allow clearance for removal of the fuel tank.
18. Carefully lower the fuel tank onto the jack.

INSTALLATION

1. Position the fuel tank on the jack.
2. Position the front parking brake cable and conduit and install the brake hose clip on the bracket.
3. Install each fuel tank support strap end into the slot above the fuel tank. Secure the opposite end of each fuel tank support strap with the fuel tank support strap bolts.
4. Tighten the fuel tank support strap bolts to 44-60 Nm (33-44 lb ft).
5. Install the fuel tank to filler pipe hose and the overflow hose on the fuel tank. Tighten the screw clamps.
6. Lower the vehicle.
7. Connect the fuel return line to the top of the fuel tank.
8. Connect the fuel supply line to the fuel pump assembly housing.
9. Place the fuel pump assembly access plate in the fuel tank opening and connect the fuel pump assembly electrical connector.
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. Start the engine. Visually inspect for leaks at all locations, and repair leaks as necessary.
14. Install the four fuel pump assembly access plate screws.
15. Fold the luggage compartment floor cover back over the fuel pump assembly access plate.
16. Install the three luggage compartment floor cover hold-down pins.
17. Install the LH quarter trim panel.
18. Install the rear seat cushion and cover.