Fuel Tank Replacement FWD

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

Notice: The fuel tank equipped with ORVR components require special handling. Follow all instructions for servicing the fuel tank as specified in the service procedures. Damage to the fuel system components and the failure to meet the Federal Regulations may result from incorrect servicing of the fuel tank.

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the catalytic converter and intermediate pipe assembly from the vehicle. Refer to Catalytic Converter Replacement .
4. Remove the 2 left side bolts (1) and the 3 right side bolts (3) from the rear exhaust heat shield (2).
5. Remove the rear exhaust heat shield (2) from the underbody.



6. Remove the 2 bolts (1) securing the parking brake cable (2) on the right side of the vehicle.



7. Disconnect the fuel supply line. Refer to Plastic Collar Quick Connect Fitting Service .
8. Disconnect the fuel tank vapor line with the quick release fitting from the fuel vapor pipe. Refer to Plastic Collar Quick Connect Fitting Service .



9. Loosen the fuel filler hose clamp (1).
10. Disconnect the fuel filler hose (2) from the fuel tank.
11. Disconnect the ORVR vent line from the fill limiter vent valve (FLVV) of the evaporative emission (EVAP) canister. Refer to Plastic Collar Quick Connect Fitting Service .



12. Remove the 4 bolts (1) and the 2 fuel tank straps (2) from the vehicle.
13. Remove the fuel tank (3) from the vehicle.

If replacing the fuel tank, remove all lines and hoses, and install on the replacement fuel tank.

1. Install the fuel tank (3) to the vehicle.

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.

2. Install the 2 fuel tank straps (2) to the vehicle with the 4 bolts (1).

Tighten
Tighten the bolts to 39 N·m (29 lb ft)




3. Connect the fuel filler hose (2) to the fuel tank.
4. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).



5. Connect the fuel supply line. Refer to Plastic Collar Quick Connect Fitting Service .
6. Connect the fuel tank vapor line with the quick release fitting to the fuel vapor pipe. Refer to Plastic Collar Quick Connect Fitting Service .
7. Connect the ORVR vent line to the FLVV on the EVAP canister.



8. Secure the parking brake cable (2) on the right side of the vehicle with 2 bolts (1).

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).




9. Install the rear exhaust heat shield (2) to the vehicle underbody.
10. Secure the rear exhaust heat shield (2) with the 2 left side bolts (1) and the 3 right side bolts (3).

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

11. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle. Refer to Catalytic Converter Replacement .
12. Lower the vehicle.
13. If the fuel sender assembly was removed refer to Fuel Sender Assembly Replacement .



14. Connect the ORVR vent line (2) to the fuel sender assembly (1).



15. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).



16. Connect the fuel supply line (1) to the fuel sender assembly.



17. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).



18. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
19. Add fuel to the fuel tank.
20. Connect the negative battery cable.

Tighten
Tighten the retainer for the negative battery cable terminal to 15 N·m (11 lb ft).

21. Pressurize the fuel system and check for leaks.
22. Install the access panel (1) to the rear seat floor panel (3).
23. Secure the access panel to the body with 4 bolts.

Tighten
Tighten the 4 bolts to 6 N·m (53 lb in).

24. Relocate the carpet under the ride side seat area and the right sill plate area.
25. Install the sill plate to the right side door opening .



26. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2).

Tighten
Tighten the 2 bolts to 41 N·m (30 lb ft).

Fuel Tank Replacement AWD

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

Notice: The fuel tank equipped with ORVR components require special handling. Follow all instructions for servicing the fuel tank as specified in the service procedures. Damage to the fuel system components and the failure to meet the Federal Regulations may result from incorrect servicing of the fuel tank.

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the propeller shaft from the vehicle. Refer to Two-Piece Propeller Shaft Replacement in Propeller Shaft.
4. Remove the catalytic converter and intermediate pipe assembly from the vehicle. Refer to Catalytic Converter Replacement in Engine Exhaust.
5. Remove the 4 rivets (2) securing the rear exhaust heat shield (3) to the vehicle.
6. Remove the rear exhaust heat shield (3) from the fuel tank (1).
7. Remove the EVAP canister (2). Refer to Evaporative Emission Canister Replacement .



8. Disconnect the fuel supply line. Refer to Plastic Collar Quick Connect Fitting Service .



9. Loosen the fuel filler hose clamp (1).
10. Disconnect the fuel filler hose (2) from the fuel tank.



11. Disconnect the 2 filler pipe vent lines (2) from the fuel tank.
12. Support the fuel tank with a transmission jack or other suitable fixture.
13. Remove the four bolts (3) and the two fuel tank straps (1) from the vehicle.
14. Remove the fuel tank from the vehicle.
15. If replacing the fuel tank, remove all lines, hoses, and component parts, and install on the replacement fuel tank.

1. Install the fuel tank to the vehicle.

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.

2. Install the 2 fuel tank straps (1) to the vehicle with the four bolts (3).

Tighten
Tighten the bolts to 39 N·m (29 lb ft).

3. Connect the 2 filler pipe vent lines (2) to the fuel tank.



4. Connect the fuel filler hose (2) to the fuel tank.
5. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).
6. Connect the fuel supply line. Refer to Plastic Collar Quick Connect Fitting Service .



7. Secure the parking brake cable (3) on the EVAP canister (2) side of the vehicle with 3 bolts (1).

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).




8. Secure the parking brake cable (2) on the left side of the vehicle with 3 bolts (1).

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

9. Install the EVAP canister to the vehicle. Refer to Evaporative Emission Canister Replacement .



10. Install the rear exhaust heat shield (3) to the fuel tank (1).
11. Secure the rear exhaust heat shield (3) with four rivets (2).
12. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement in Propeller Shaft.
13. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle. Refer to Catalytic Converter Replacement in Engine Exhaust.
14. Lower the vehicle.



15. Install the fuel supply line (1) to the fuel sender fitting.
16. Secure the fuel supply line (1) with the retaining clip (2).



17. Connect the fuel sender electrical connector (1) to the fuel sender assembly.
18. Add fuel to the fuel tank.
19. Connect the negative battery cable.

Tighten
Tighten the retainer for the negative battery cable terminal to 15 N·m (11 lb ft).

20. Pressurize the fuel system and check for leaks.
21. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
22. Install the access panel to the rear seat floor.
23. Install the sill plate to the left side door opening.
24. Install the rear seat bottom cushion. Refer to Rear Seat Cushion Replacement in Seats.