Removal and Installation

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 fuel from the fuel tank. Fuel Tank Draining
3. Disconnect battery ground cable.

NOTE: When the battery has been disconnected or reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

4. Raise vehicle on hoist. Use proper vehicle lifting procedures.
5. Remove the screw retaining the fuel tank filler pipe retainer to the fuel tank flange.
6. Remove fuel tube clips retainers.
7. Using Fuel Line Disconnect Tool Set T90T-9550-S, disconnect push connect fittings for fuel supply and vapor tube at fuel pump module.
8. Disconnect vapor hoses electrical connector to the fuel pump module.
9. Place a safety support under the fuel tank. Remove the nuts from one end of the fuel tank mounting straps. The fuel tank mounting straps are hinged and will swing Out of the way.
10. Remove fuel tank. If required, remove fuel pump module.






INSTALLATION

1. Before proceeding, check the following:
a. Leak check the fuel pump module.
b. Verify evaporative emission valve is properly installed on top of the fuel tank.
c. Make sure clips are installed properly on tank flange. Make sure vapor tubes are secured into clips.
d. Make all required connections which will be inaccessible after the fuel tank is installed.

NOTE: If fuel pump module has been removed, the O-ring seal must be replaced.

2. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel tank filler pipe with water base tire-mounting lubricant. Install the fuel tank onto the fuel tank filler pipe then bring the fuel tank into final position.

NOTE: If required, tape hoses and wiring to fuel tank top, to verify they are correctly routed and will not be pinched between fuel tank and body.

3. Bring fuel tank mounting straps around the fuel tank and start the retaining nut. Align fuel tank with the fuel tank mounting straps and check clearance to frame and underbody.
4. Check the hoses and wiring mounted on the fuel tank top to make sure they are correctly routed and will not be pinched between the fuel tank and body.
5. Tighten the fuel tank mounting strap retaining nuts to 30-40 Nm (23-29 lb ft).
6. Fasten fuel tank filler pipe retainer, if removed. Tighten screws to 6.8-9.2 Nm (61-81 lb in).
7. Reconnect the fuel supply and vapor tube and vapor hoses. Make sure the fuel supply, fuel return, and vapor connections are made correctly. If necessary, trace the various lines to the engine and refer to the illustrations to make sure the proper tubes are connected.
8. Install fuel tube clip retainers.
9. Connect fuel pump module electrical connector.
10. Lower vehicle.
11. Replace fuel drained from the fuel tank. Fuel Tank Draining
12. Connect battery ground cable.
13. Check all connections for leaks.