Removal and Replacement
Fuel Tank Removal/InstallationWARNING: Compressed natural gas is flammable and highly explosive. You could be killed or seriously injured if leaking natural gas is ignited.
Stop the engine, and keep heat, sparks, and flames away.
NOTE:
- You must be an SCI-certified technician to do fuel tank inspection or replacement work.
- This procedure degrades the integrity of the fuel tank. If you do it, do not reinstall the original fuel tank. Install a new one.
- Wear gloves while handing the fuel tank.
Removal/Installation
1. Relieve fuel pressure between the engine and the fuel tank.
2. Lift the vehicle, and support it with jackstands.
3. Remove the under-floor cover (A).
4. Remove the three fuel pipes (A) at the fuel joint block (B) and the two fuel joint block mounting. bolts (C).
NOTE:
- Always use two wrenches when removing or installing fuel pipe nuts.
- Apply silicone oil or polyalkyleneglycol (PAG) oil to a new O-ring (D) and carefully install it into its proper position.
5. Lower the vehicle. Remove the left-rear door. then disconnect the connector (A).
6. Remove the rear seat.
7. Remove the rear seat belt,
8. Remove the rear pillar trim,
9. Remove the rear shelf and the trunk floor lid.
10. Remove the trunk partition.
11. Remove the gussets (A).
12. Remove the harness clip (A) and the rear parcel cover (B).
13. Remove the harness clip (A) and the rear shelf gussets (B).
14. Remove the rear floor upper cross-member gusset.
15. Remove the bolts (A).
16. Disconnect the vent hose (A) from the fuel tank (B).
17. Remove the tank frame mounting bolts (A). FRONT
18. Push the front seats forward, then cover the seats and floor with a tarp or similar material.
19. With the help of two other technicians, lift the frame, and slide the entire fuel tank assembly (A) into the passenger compartment. Be careful not to damage the fuel joint block.
20. Rotate the fuel tank so the fuel joint block and the frame can clear the door opening, then carefully remove the fuel tank assembly from the vehicle.
21. Install the new fuel tank assembly in the reverse order of removal.
NOTE: Do this when you install the left rear door:
- Tighten the door checker mounting bolt,
- Adjust the door position,
22. Open the manual look-down valves on the new tank. (New tank come with these valves closed).
23. Do the leak inspection procedure.
Fill Procedure
If a tank has less than 690 ± 340 kPa (7.0 ± 3.5 kgf/sq.cm, 100 ± 50 psi) of internal pressure and is at an ambient temperature of 32 °F (0 °C)or less, follow the procedure below. Otherwise, fill the tank normally.
1. Fill the fuel tank to 4,800 ± 340 kPa (49.2 ± 3.5 kgf/sq.cm, 700 ± 50 psi) slowly (from a compressor, not from a cascade storage system).
2. Wait 1 hour.
3. Fill the rest of the tank normally.