Removal and Replacement

Fuel Tank Removal/Installation

WARNING
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 fuel tank and the engine. Fuel Pressure Relieving - Between The Fuel Tank and The Engine

2. Raise the vehicle on a lift.

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. Testing and Inspection

- Apply silicone oil or polyalkyleneglycol (PAG) oil to the new O-rings (D), and carefully install them into their proper positions. Service and Repair





5. Lower the vehicle. Remove the left-rear door, Service and Repair then disconnect the connector (A).

6. Remove the rear seat. Rear Seat Removal/Installation

7. Remove the rear seat belt. Rear Seat Belt Replacement

8. Remove the C-pillar trim. Interior Trim Removal/Installation - C-Pillar Trim (4-Door)

9. Remove the rear shelf Service and Repair and the trunk floor lid. Interior Trim Removal/Installation - Trunk Area

10. Remove the trunk partition. Interior Trim Removal/Installation - Trunk Area






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. Service and Repair






15. Remove the bolts (A).






16. Disconnect the vent hose (A) from the fuel tank (B).






17. Remove the tank frame mounting bolts (A).

18. Push the front seats forward, then cover the seats and the 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. Service and Repair

- Adjust the door position. Adjustments

22. Open the manual lock-down valves on the new tank. (New tank come with these valves closed).

23. Do the leak inspection procedure. Testing and Inspection






Fill Procedure

If a tank has less than 690±340 kPa (7.0±3.5 kgf/cm2, 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/cm2, 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.