Fuel Tank Replacement Front Tank

Important: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Disconnect the EVAP vent line from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .



4. Disconnect the vapor line (1) from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .



5. Disconnect the fuel feed and EVAP lines from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .



6. Open the clip on the side of the fuel tank retaining the intermediate lines.
7. Disconnect the fuel and EVAP intermediate lines from the front tank. Refer to Plastic Collar Quick Connect Fitting Service .
8. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.



9. If equipped, remove the fuel tank shield bolts.
10. If equipped, remove the fuel tank shield.



11. 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.

12. Remove the fuel tank strap bolts.
13. Remove the fuel tank straps.
14. With the aid of an assistant, carefully lower the fuel tank until the sending unit is accessible.



15. Disengage the connector position assurance (CPA) retainer.
16. Disconnect the sending unit electrical connector.
17. Completely lower the fuel tank.
18. Place the fuel tank in a suitable work area.
19. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement .

1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement .
2. Place the fuel tank onto a suitable jack.
3. With the aid of an assistant, partially raise the fuel tank.
4. Connect the sending unit electrical connector.
5. Engage the CPA retainer.



6. With the aid of an assistant, completely raise the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the fuel tank straps.
8. Install the fuel tank strap bolts.

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

9. Remove the adjustable jack from under the fuel tank.



10. If equipped, install the fuel tank shield.
11. If equipped, install the fuel tank shield bolts.

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




12. Remove the caps from the fuel and EVAP lines.
13. Connect the fuel and EVAP intermediate lines to the front tank. Refer to Plastic Collar Quick Connect Fitting Service .
14. Close the clip on the side of the fuel tank retaining the intermediate lines.



15. Connect the fuel feed and EVAP lines to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .



16. Connect the vapor line (1) to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .



17. Connect the EVAP vent line to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
18. Install the fuel fill hose to the fuel tank.
19. Tighten the fuel fill hose clamp at the fuel tank.

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

20. Lower the vehicle.
21. Refill the fuel tank.
22. Install the fuel fill cap.
23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
24. Use the following procedure in order to inspect for leaks:

24.1.

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

24.2.

Turn the ignition OFF for 10 seconds.

24.3.

Turn the ignition ON, with the engine OFF.

24.4.

Inspect for fuel leaks.

Fuel Tank Replacement Rear Tank

Important: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.

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.
4. Drain the fuel tank. Refer to Fuel Tank Draining .
5. Remove the rear exhaust insulator.



6. Remove the spare tire hoist crossmember bolts and crossmember.



7. Disconnect the EVAP canister quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .



8. Disconnect the fuel and EVAP intermediate lines from the front tank. Refer to Plastic Collar Quick Connect Fitting Service .



9. Disconnect the fuel pressure sensor electrical connector (1).



10. Support the fuel tank with a suitable jack.
11. Remove the fuel tank strap bolts.

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

12. Remove the fuel tank straps.
13. With the aid of an assistant, lower the rear tank until the intermediate line connections can be reached.



14. Disconnect the fuel and EVAP intermediate lines from the rear tank. Refer to Plastic Collar Quick Connect Fitting Service .
15. Remove the fuel and EVAP intermediate lines.
16. Cap the fuel and EVAP lines in order to prevent possible EVAP/fuel system contamination.



17. Disconnect the sending unit electrical connector (2).
18. Completely lower the fuel tank.
19. With the aid of an assistant, remove the tank from the jack.
20. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement .

1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement .
2. With the aid of an assistant, install the tank onto the jack.
3. Partially raise the fuel tank.
4. Connect the sending unit electrical connector (2).



5. Remove the caps from the fuel and EVAP lines.
6. Install the fuel and EVAP intermediate lines.
7. Connect the fuel and EVAP intermediate lines to the rear tank. Refer to Plastic Collar Quick Connect Fitting Service .



8. With the aid of an assistant, completely raise the rear tank.

Notice: Refer to Fastener Notice in the Preface section.

9. Install the fuel tank straps.
10. Install the fuel tank strap bolts.

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

11. Remove the adjustable jack from under the fuel tank.



12. Connect the fuel pressure sensor electrical connector (1).



13. Connect the fuel and EVAP intermediate lines to the front tank. Refer to Plastic Collar Quick Connect Fitting Service .



14. Connect the EVAP canister quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .



15. Install the spare tire hoist crossmember and bolts.

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




16. Install the rear exhaust insulator.
17. Install the spare tire.



18. Install the spare tire stowage lock cylinder.



19. Install the fuel tank filler housing.
20. Install the fuel tank filler housing to fuel tank fill pipe bolts.

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




21. Install the fuel tank filler housing to body TORX® screws (1) and retainer (2).

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

22. Refill the fuel tank.
23. Install the fuel fill cap.
24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
25. Use the following procedure in order to inspect for leaks:

25.1.

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

25.2.

Turn the ignition OFF for 10 seconds.

25.3.

Turn the ignition ON, with the engine OFF.

25.4.

Inspect for fuel leaks.