Fuel Tank Replacement with E26
Removal Procedure
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief.
- Drain the fuel tank. Refer to
Fuel Tank Draining.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Disconnect the fuel fill pipe evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank EVAP line. Refer to
Plastic Collar Quick Connect Fitting Service.
- Loosen the fuel fill hose clamp (2) at the fuel tank and remove the hose from the tank.
- Clean the fuel and EVAP pipe connections and the surrounding areas prior to disconnecting the lines in order to avoid possible contamination of the fuel and or EVAP system.
- Disconnect the chassis fuel feed pipe quick connect fitting (2) from the fuel tank fuel feed pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the EVAP canister purge pipe quick connect fitting (1) from the chassis EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid valve.
- Support the fuel tank with an adjustable jack.
- Remove the fuel tank strap bolts (1).
- Remove the fuel tank straps (2).
- With the aid of an assistant, carefully lower the fuel tank (3) until the fuel tank module connections can be accessed.
- Disconnect the chassis wiring harness electrical connectors from the fuel tank pressure sensor and fuel tank module.
- With the aid of the assistant, completely lower the fuel tank.
- With the aid of the assistant, place the fuel tank in a suitable work area.
- If replacing the fuel tank proceed to the next step, otherwise proceed to step 15 in the installation procedure.
- Remove the fuel tank shield push on retainers (2).
- Remove the fuel tank shield (1) from the fuel tank clips.
- Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the fuel feed pipe from the fuel tank clips (2 and 3).
- Remove the fuel feed pipe (1) from under the EVAP front pipe.
- Disconnect the EVAP front pipe quick connect fittings from the fuel tank module and roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the EVAP front pipe (1) from under the EVAP pipe.
- Disconnect the EVAP pipe quick connect fitting from the fuel tank roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the adhesive tape securing the EVAP pipe to the fuel tank, if necessary.
- Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the EVAP pipe quick connect fitting from the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the EVAP pipe (1) from the fuel tank retainers (2, 3, and 4).
- Remove the EVAP canister. Refer to
Evaporative Emission Canister Replacement.
- Remove the fuel tank module. Refer to
Fuel Tank Fuel Pump Module Replacement.
Installation Procedure
- Install the fuel tank module. Refer to
Fuel Tank Fuel Pump Module Replacement.
- Install the EVAP canister. Refer to
Evaporative Emission Canister Replacement.
- Install the EVAP pipe (1) to the fuel tank retainers (2, 3, and 4).
- Connect the EVAP pipe quick connect fitting to the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the EVAP pipe quick connect fitting to the fuel tank roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Secure the EVAP pipe to the fuel tank with adhesive tape, if necessary.
- Install and route the EVAP front pipe (1) under the EVAP line.
- Connect the EVAP front pipe quick connect fittings to the fuel tank module and roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Install and route the fuel feed pipe (1) under the EVAP front pipe.
- Connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Install the fuel feed pipe to the fuel tank clips (2 and 3).
- Install the fuel tank shield onto the tank clips (1).
- Install the fuel tank shield push on retainers (2).
- With the aid of an assistant, place the fuel tank on the adjustable jack.
- With the aid of the assistant, carefully raise the fuel tank (3) until the fuel tank module connections can be made.
- Connect the chassis wiring harness electrical connectors to the fuel tank pressure sensor and fuel tank module.
- With the aid of the assistant, completely raise the fuel tank.
- Install the fuel tank straps (2).
Caution: Refer to Fastener Caution in the Preface section.
- Install the fuel tank strap bolts (1) and tighten to
25 N·m (18 lb ft).
- Remove the adjustable jack from under the fuel tank.
- Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid valve.
- Connect the EVAP canister purge pipe quick connect fitting (1) to the chassis EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the fuel feed pipe quick connect fitting (2) to the fuel tank fuel feed pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Install the fuel tank fill hose to the fuel tank.
- Connect the fuel fill pipe EVAP line quick connect fitting (1) to the fuel tank EVAP line. Refer to
Plastic Collar Quick Connect Fitting Service.
- Tighten the fuel fill hose clamp (2) at the fuel tank to
2.75 N·m (24 lb in).
- Refill the fuel tank.
- Install the fuel cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Perform the following procedure in order to inspect for leaks:
31.1. | Turn the ignition ON, with the engine OFF, for 2 seconds. |
31.2. | Turn the ignition OFF for 10 seconds. |
31.3. | Turn the ignition ON, with the engine OFF. |
31.4. | Inspect for fuel leaks. |
Fuel Tank Replacement without E26
Removal Procedure
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief.
- Drain the fuel tank. Refer to
Fuel Tank Draining.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Disconnect the fuel fill pipe evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank EVAP line. Refer to
Plastic Collar Quick Connect Fitting Service.
- Loosen the fuel fill hose clamp (2) at the fuel tank and remove the hose from the tank.
- Clean the fuel and EVAP pipe connections and the surrounding areas prior to disconnecting the lines in order to avoid possible contamination of the fuel and or EVAP system.
- Disconnect the chassis fuel feed pipe quick connect fitting (2) from the fuel tank fuel feed pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the EVAP canister purge pipe quick connect fitting (1) from the chassis EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid valve.
- Support the fuel tank with an adjustable jack.
- Remove the fuel tank strap bolts (1).
- Remove the fuel tank straps (2).
- With the aid of an assistant, carefully lower the fuel tank (3) until the fuel tank module connections can be accessed.
- Disconnect the chassis wiring harness electrical connectors from the fuel tank pressure sensor and fuel tank module.
- With the aid of the assistant, completely lower the fuel tank.
- With the aid of the assistant, place the fuel tank in a suitable work area.
- If replacing the fuel tank proceed to the next step, otherwise proceed to step 15 in the installation procedure.
- Remove the fuel tank shield push on retainers (2).
- Remove the fuel tank shield (1) from the fuel tank clips.
- Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the fuel feed pipe from the fuel tank clips (2 and 3).
- Remove the fuel feed pipe (1) from under the EVAP front pipe.
- Disconnect the EVAP front pipe quick connect fittings from the fuel tank module and roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the EVAP front pipe (1) from under the EVAP pipe.
- Disconnect the EVAP pipe quick connect fitting from the fuel tank roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the adhesive tape securing the EVAP pipe to the fuel tank, if necessary.
- Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the EVAP pipe quick connect fitting from the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service.
- Remove the EVAP pipe (1) from the fuel tank retainers (2, 3, and 4).
- Remove the EVAP canister. Refer to
Evaporative Emission Canister Replacement.
- Remove the fuel tank module. Refer to
Fuel Tank Fuel Pump Module Replacement.
Installation Procedure
- Install the fuel tank module. Refer to
Fuel Tank Fuel Pump Module Replacement.
- Install the EVAP canister. Refer to
Evaporative Emission Canister Replacement.
- Install the EVAP pipe (1) to the fuel tank retainers (2, 3, and 4).
- Connect the EVAP pipe quick connect fitting to the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the EVAP pipe quick connect fitting to the fuel tank roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Secure the EVAP pipe to the fuel tank with adhesive tape, if necessary.
- Install and route the EVAP front pipe (1) under the EVAP line.
- Connect the EVAP front pipe quick connect fittings to the fuel tank module and roll over valve. Refer to
Plastic Collar Quick Connect Fitting Service.
- Install and route the fuel feed pipe (1) under the EVAP front pipe.
- Connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Install the fuel feed pipe to the fuel tank clips (2 and 3).
- Install the fuel tank shield onto the tank clips (1).
- Install the fuel tank shield push on retainers (2).
- With the aid of an assistant, place the fuel tank on the adjustable jack.
- With the aid of the assistant, carefully raise the fuel tank (3) until the fuel tank module connections can be made.
- Connect the chassis wiring harness electrical connectors to the fuel tank pressure sensor and fuel tank module.
- With the aid of the assistant, completely raise the fuel tank.
- Install the fuel tank straps (2).
Caution: Refer to Fastener Caution in the Preface section.
- Install the fuel tank strap bolts (1) and tighten to
25 N·m (18 lb ft).
- Remove the adjustable jack from under the fuel tank.
- Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid valve.
- Connect the EVAP canister purge pipe quick connect fitting (1) to the chassis EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the fuel feed pipe quick connect fitting (2) to the fuel tank fuel feed pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Install the fuel tank fill hose to the fuel tank.
- Connect the fuel fill pipe EVAP line quick connect fitting (1) to the fuel tank EVAP line. Refer to
Plastic Collar Quick Connect Fitting Service.
- Tighten the fuel fill hose clamp (2) at the fuel tank to
2.75 N·m (24 lb in).
- Refill the fuel tank.
- Install the fuel cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Perform the following procedure in order to inspect for leaks:
31.1. | Turn the ignition ON, with the engine OFF, for 2 seconds. |
31.2. | Turn the ignition OFF for 10 seconds. |
31.3. | Turn the ignition ON, with the engine OFF. |
31.4. | Inspect for fuel leaks. |