Removal and Replacement
Fuel Tank
Special Service Tools
Wrench, Fuel Tank Module
310-118(LRT-19-009)
Removal
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
1. Raise and support the vehicle.
2. Disconnect the battery ground cable.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
3. Drain the fuel tank.
4. Release the LH and RH rear shock absorbers from the body.
^ Remove the 6 nuts.
5. Release the RH fuel tank access cover.
^ Remove the 4 nuts.
^ Disconnect the electrical connector.
6. Disconnect the low tire pressure monitoring system rear antenna electrical connector.
NOTE: Wheel shown removed for clarity.
7. Remove the RH rear fender splash shield.
^ Remove the 2 clips securing the rear fender splash shield to the rocker panel and rear bumper.
^ Remove the nut.
^ Remove the 4 bolts.
^ Remove the fender seal.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
8. Release the fuel tank breather hose from the fuel tank filler pipe.
^ Remove and discard the hose clip.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
9. Release the evaporative emissions vent pipe.
^ Remove and discard the hose clip.
^ Install blanking caps to the exposed ports.
10. Release the breather hose and vent hose from the securing clip.
^ Withdraw the breather hose and vent hose from the body during the fuel tank lowering procedure.
11. Remove the rear driveshaft.
12. Remove the fuel tank shields.
^ Remove the 14 bolts.
^ Remove the 4 nuts.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
13. Remove the evaporative emissions canister.
^ Remove the 2 bolts.
^ Disconnect the 3 quick release connectors.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
14. Disconnect the 2 fuel lines.
^ Position a container to collect the fuel spillage.
^ Disconnect the 2 quick release connectors.
^ Install blanking caps to the exposed ports.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
15. Release the fuel tank filler pipe from the fuel tank filler hose.
^ Release the hose clip.
^ Install blanking caps to the exposed ports.
NOTE: Right-hand shown, left-hand similar.
16. Disconnect both rear suspension height sensor electrical connectors.
17. Using a suitable hydraulic jack, support the rear subframe.
18. Remove the 4 rear subframe mounting bolts.
19. Lower the rear subframe to a maximum of 20 mm (0.78 inches).
20. Release the air suspension air pipes.
21. Lower the rear subframe to a maximum of 40 mm (1.57 inches).
^ Collect the spacers from the mountings.
22. With assistance, remove the fuel tank.
^ Remove the 5 bolts.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
NOTE: Do not disassemble further if the component is removed for access only.
23. Remove the fuel lines.
^ Release from the 8 clips.
^ Disconnect the quick release connector.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
24. Release the fuel vapor separator lines.
^ Release from the 6 clips.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
25. Remove the fuel tank vapor separator.
^ Remove the 2 clips.
^ Remove and discard the hose clip.
^ Release the hose.
^ Disconnect the 2 quick release connectors.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
26. Remove the fuel filter.
^ Using the special tool, remove the fuel pump access port locking ring.
^ Disconnect the 3 fuel lines.
^ Disconnect the electrical connector.
^ Remove and discard the seal.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
27. Remove the fuel pump.
^ Depress the clips and release the lower part of the pump and sender unit rearward.
^ Withdraw from the fuel tank.
28. Remove the fuel tank support straps from the fuel tank.
^ Remove the 4 clips.
Installation
1. Install the fuel tank support straps to the fuel tank.
2. Install the fuel pump.
^ Secure in the clips.
3. Install the fuel filter.
^ Install a new seal.
^ Connect the fuel lines.
^ Connect the electrical connector.
^ Using the special tool, install the fuel pump access port locking ring.
4. Install the fuel tank vapor separator.
^ Install the clips.
^ Attach the hose.
^ Install a new retaining clip.
^ Connect the quick release connectors.
5. Attach the fuel vapor separator lines.
^ Secure in the clips.
6. Install the fuel lines.
^ Secure in the clips.
^ Connect the quick release connector.
7. Position fuel tank with the fuel tank breather hose and vent hose to the vehicle.
8. With assistance, install the fuel tank.
^ Tighten the bolts to 19 Nm (14 ft. lbs.).
9. Raise the rear subframe and locate on the dowels.
^ Install the spacers to the rear subframe mountings.
10. Secure the air suspension air pipes.
CAUTION: Make sure that the spacers are correctly located to the bushes prior to tightening.
11. Install the 4 rear subframe mounting bolts and tighten to 165 Nm (122 ft. lbs.)
12. Connect both rear suspension height sensor electrical connectors.
13. Install the fuel tank filler pipe to the fuel tank filler hose.
^ Remove the blanking caps from the ports.
^ Tighten the clip.
14. Connect the fuel lines.
15. Install the evaporative emissions canister.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
^ Remove the blanking caps from the ports.
^ Connect the quick release connectors.
16. Install the fuel tank shields.
^ Tighten the nuts and bolts to 25 Nm (18 ft. lbs.).
17. Install the rear driveshaft.
18. Secure the breather hose and vent hose to the securing clip.
19. Secure the evaporative emission vent pipe.
^ Remove the blanking caps from the ports.
20. Secure the breather hose to the fuel tank filler pipe.
^ Remove the blanking caps from the ports.
^ Tighten the clip.
21. Install the RH rear fender splash shield.
^ Install the clips.
^ Install the bolts.
^ Install the nut.
^ Install the fender seal.
22. Connect the low tire pressure monitoring system rear antenna electrical connector.
23. Install the RH fuel tank access cover.
^ Install the electrical connector.
^ Install the nuts.
24. Secure the rear shock absorbers to the body.
^ Tighten the nuts to 56 Nm (41 ft. lbs.).
25. Fill the fuel tank with the amount recovered during the fuel tank drain procedure.
26. Connect the battery ground cable.