Fuel Tank Replacement Front Tank

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the fuel tank filler housing to body screws (1), and retainer (2).



3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
4. Remove the fuel tank filler housing.



5. Drain the fuel tank. Refer to Fuel Tank Draining .
6. Disconnect the EVAP vent pipe (3) from the EVAP canister clip.
7. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission Canister Replacement .



8. Loosen the vent hose clamp at the front tank.
9. Remove the vent hose from the front tank.



10. Loosen the fuel tank fill hose clamp.
11. Remove the fuel tank fill hose from the front tank.



12. Remove the fuel tank shield bolts.
13. Remove the fuel tank shield.



14. Using an adjustable jack, support the fuel tank.

Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

15. Remove the fuel tank strap bolts.
16. Remove the fuel tank straps.
17. With the aid of an assistant, carefully lower the fuel tank slightly.



18. Remove the sending unit shield nuts.
19. Remove the sending unit shield.



20. Disconnect the fuel feed, return, and EVAP pipes from the sending unit. Refer to Plastic Collar Quick Connect Fitting Service .



21. Disconnect the sending unit electrical connector (2).
22. Remove the fuel tank.
23. Place the fuel tank in a suitable work area.
24. Disconnect the EVAP pipe from the fuel tank roll over valve and retaining clip.
25. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement .
26. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.

1. Remove the caps from the fuel and EVAP pipes.
2. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement .
3. Connect the EVAP pipe to the fuel tank roll over valve and retaining clip.
4. Place the fuel tank onto a suitable jack.
5. With the aid of an assistant, partially raise the fuel tank.
6. Connect the sending unit electrical connector (2).



7. Connect the fuel feed, return, and EVAP pipes to the sending unit. Refer to Plastic Collar Quick Connect Fitting Service .



8. Install the sending unit shield.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

9. Install the sending unit shield nuts.

Tighten
Tighten the nuts to 10 N·m (89 lb in).




10. With the aid of an assistant, completely raise the fuel tank.
11. Install the fuel tank straps.
12. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

13. Remove the adjustable jack from the fuel tank.



14. Install the fuel tank shield.
15. Install the fuel tank shield bolts.

Tighten
Tighten the bolts to 15 N·m (11 lb ft).




16. Install the fuel tank fill hose to the front tank.
17. Tighten the fuel tank fill hose clamp.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).




18. Install the vent hose to the front tank.
19. Tighten the vent hose clamp at the front tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).




20. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .
21. Connect the EVAP vent pipe (3) to the EVAP canister clip.



22. Install the fuel tank filler housing.
23. Install the fuel tank filler housing to the fuel tank fill pipe screws.

Tighten
Tighten the screws to 2.3 N·m (20 lb in).




24. Install the fuel tank filler housing to body screws (1), and retainer (2).

Tighten
Tighten the screws to 2.3 N·m (20 lb in).

25. Lower the vehicle.
26. Refill the fuel tank.
27. Install the fuel fill cap.
28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
29. Use the following procedure in order to inspect for leaks:

29.1.

Turn the ignition ON, with the engine OFF, for 2 seconds.

29.2.

Turn the ignition OFF for 10 seconds.

29.3.

Turn the ignition ON, with the engine OFF.

29.4.

Inspect for fuel leaks.

Fuel Tank Replacement Rear Tank

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Remove the spare tire stowage lock cylinder.



3. Remove the spare tire from the hoist.
4. Remove the rear exhaust hanger bolts and hanger.



5. Remove the spare tire hoist crossmember and bolts.
6. Drain the fuel tank. Refer to Fuel Tank Draining .



7. Loosen the fuel tank fill hose clamp at the front tank.
8. Separate the fill hose from the front tank.



9. Remove the fuel pipe ground strap bolt.
10. Separate the ground straps (1, 2).



11. Loosen the fuel tank vent hose clamp at the rear tank.
12. Separate the vent hose from the rear tank.



13. Loosen the fuel tank fill pipe clamp at the rear tank.
14. Separate the fill pipe from the rear tank.
15. Loosen the vent hose clamp at the rear tank.
16. Separate the vent hose from the rear tank.
17. Lower the vehicle.



18. Remove the fuel tank filler housing to body screws (1), and retainer (2).



19. Remove the fuel tank filler housing to fuel tank fill pipe screws.
20. Remove the fuel tank filler housing from the vehicle.
21. Remove the fuel fill pipe from the vehicle.
22. Raise the vehicle.
23. Support the fuel tank with a suitable jack.



24. Remove the fuel tank strap bolts.

Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

25. Remove the fuel tank straps.
26. With the aid of an assistant, partially lower the rear tank.



27. Open the retaining clip.
28. Remove the hose from the retaining clip.
29. Remove the evaporative emission (EVAP) and fuel pipes from the retaining clip.



30. Loosen the fuel tank fill hose clamp at the rear tank.
31. Remove the fuel tank fill hose from the rear tank.



32. Disconnect the EVAP tubes (2) at the EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .
33. Disconnect the fuel pipe at the fuel sending unit (1). Refer to Metal Collar Quick Connect Fitting Service .
34. Cap the EVAP and fuel pipes in order to prevent possible fuel/EVAP system contamination.



35. Disconnect the fuel tank electrical connector.
36. Completely lower the fuel tank.
37. With the aid of an assistant, remove the tank from the jack.
38. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement .
39. Remove the EVAP pipes from the fuel tank rollover valve and retaining clips, if required.

1. Install the EVAP pipes to the fuel tank rollover valves and retaining clips, if required.
2. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement .
3. With the aid of an assistant, install the tank to the jack.
4. Partially raise the fuel tank.
5. Connect the fuel tank electrical connector.



6. Remove the caps from the EVAP and fuel pipes.
7. Connect the fuel pipe at the fuel sending unit (1). Refer to Metal Collar Quick Connect Fitting Service .
8. Connect the EVAP tubes (2) at the EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .



9. Install the fuel tank fill hose to the rear tank.
10. Position the hose clamp downwards, for easy access.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

11. Tighten the fuel tank fill hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).




12. Install the EVAP and fuel pipes to the retaining clip.
13. Install the hose to the retaining clip.
14. Close the retaining clip.
15. With the aid of an assistant, fully raise the rear tank.



16. Install the fuel tank straps.
17. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

18. Remove the jack from the fuel tank.
19. Lower the vehicle.



20. Install the fuel fill pipe to the vehicle.
21. Install the fuel tank filler housing to the vehicle.
22. Install the fuel tank filler housing to fuel tank fill pipe screws.

Tighten
Tighten the screws to 2.3 N·m (20 lb in).




23. Install the fuel tank filler housing to body screws (1), and retainer (2).

Tighten
Tighten the screws to 2.3 N·m (20 lb in).

24. Raise the vehicle.



25. Install the vent hose to the rear tank.
26. Tighten the vent hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).

27. Install the fill pipe to the rear tank.
28. Tighten the fuel tank fill pipe hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).




29. Install the vent hose to the rear tank.
30. Tighten the vent hose clamp at the rear tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).




31. Position the ground straps (1, 2).
32. Install the fuel pipe ground strap bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




33. Install the fill hose to the front tank.
34. Tighten the fill hose clamp at the front tank.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).




35. Install the spare tire hoist crossmember and bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

36. Install the rear exhaust hanger and bolts.

Tighten
Tighten the bolts to 30 N·m (22 lb ft).

37. Lower the vehicle.



38. Install the spare tire to the hoist.



39. Install the spare tire stowage lock cylinder.
40. Refill the fuel tank.
41. Install the fuel fill cap.
42. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
43. Using the following procedure in order to inspect for leaks:

43.1.

Turn the ignition OFF, with the engine OFF, for 2 seconds.

43.2.

Turn the ignition ON for 10 seconds.

43.3.

Turn the ignition OFF, with the engine OFF.

43.4.

Inspect for fuel leaks.