Removal and Replacement
Fuel Tank
Service Repair No - 19.55.01
Removal
WARNING:
^ place the vehicle in a well ventilated, quarantined area and arrange 'No smoking/petrol fumes' signs about the vehicle.
^ Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
^ Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
^ The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
1. Disconnect the battery ground cable.
2. Drain the fuel tank.
3. Raise and support the vehicle.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
4. Remove the fuel tank heat shield.
^ Remove the 3 bolts and 2 nuts.
5. Disconnect the fuel filler neck from the filler neck hose.
^ Remove the tamper proof cover.
^ Remove and discard the hose clip.
CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.
6. Disconnect the fuel supply and purge lines quick release connections at the front of the fuel tank.
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
7. Disconnect the fuel tank vent line.
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
8. Release the fuel tank harness.
9. Release the parking brake emergency release cable.
^ Release from the 4 clips.
10. Remove the 2 emergency release cable clips.
11. Using a transmission jack, lower the fuel tank sufficiently only to access the top of the fuel tank.
^ Remove the 6 bolts.
WARNING: Secure the component to the transmission jack.
CAUTION:
^ Do not lower the fuel tank more than 250 mm (9.75 in)
^ Note the rear bolt is fitted with 2 washers.
12. Disconnect the fuel pump module electrical connector.
13. Release the purge line from the top of the fuel tank.
^ Remove the adhesive pad.
^ Release from the 5 clips.
14. Remove the fuel tank.
15. With assistance, remove the fuel tank from the transmission jack.
NOTE: Do not disassemble further if the component is removed for access only.
16. Remove the fuel tank vent line.
^ Disconnect the quick release connector.
^ Remove from the 3 clips.
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
17. Remove the fuel supply line.
^ Disconnect the quick release connector.
^ Release from the 2 clips.
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
18. Release the fuel pump module access flange.
^ Loosen the screw.
^ Remove the clamp.
CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
NOTE: Note the fitted position.
19. Remove the fuel pump module access flange.
^ Disconnect the vent line.
^ Disconnect the fuel supply line.
^ Disconnect the 3 electrical connectors.
^ Remove and discard the seal.
CAUTION: Before disconnecting or removing components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
20. Remove the fuel pump module.
^ Release the strap.
^ Release the fuel pressure regulator.
^ Disconnect the 2 fuel lines.
21. Remove the fuel tank front fuel level sender unit.
^ Release the lead.
^ Release the clip.
22. Remove the fuel filler hose.
^ Remove the tamper proof cover.
^ Remove and discard the hose clip.
CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.
23. Remove the fuel tank bracket.
^ Remove the 2 clips.
^ Remove the 2 bolts.
^ Remove the retaining plate.
Installation
1. Install the fuel tank bracket.
^ Install the retaining plate.
^ Install the clips.
^ Tighten the bolts to 3.5 Nm (2.5 ft. lbs.).
2. Install the fuel filler hose.
^ Install a new retaining clip.
CAUTION: Tighten the new tamper proof clip until the hexagon shears.
3. Install the fuel tank front fuel level sender unit.
^ Secure the clip.
^ Secure the lead.
4. Install the fuel pump module.
^ Connect the fuel lines.
^ Secure with the strap.
^ Secure the fuel pressure regulator.
5. Install the fuel pump module access flange.
^ Clean the component mating faces.
^ Install a new seal.
^ Connect the 3 electrical connectors.
^ Connect the fuel supply line.
^ Connect the vent line.
6. Secure the fuel pump module access flange.
^ Install the clamp.
^ Tighten the screw to 4 Nm (3 ft. lbs.).
CAUTION: Make sure the seal is installed correctly.
7. Install the fuel supply line.
^ Connect the quick release connector.
^ Secure in the 2 clips.
8. Install the vent line.
^ Connect the quick release connector.
^ Secure in the 3 clips.
9. With assistance, install the fuel tank to the transmission jack.
10. Position the fuel tank to the vehicle.
11. Secure the purge line to the fuel tank.
^ Secure with the clips.
^ Install the adhesive pad.
12. Connect the electrical connector.
13. Install the fuel tank.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
CAUTION: Note the rear bolt is fitted with 2 washers.
14. Install the 2 emergency release cable clips.
15. Secure the parking brake emergency release cable.
^ Secure in the 4 clips.
16. Secure the fuel tank harness.
17. Connect the vent line.
18. Connect the fuel supply and purge lines.
19. Connect the fuel filler neck.
^ Install a new retaining clip.
CAUTION: Tighten the new tamper proof clip until the hexagon shears.
20. Install the fuel tank heat shield.
^ Tighten the bolts to 6 Nm (4 ft. lbs.).
^ Tighten the nuts to 3 Nm (2 ft. lbs.).
21. Refill the fuel tank.