Fuel Tank

Special Tool(s)

Powertrain Lift 300-OTC1585AE or equivalent

Removal and Installation

 WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

 WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

 WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

 WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

 WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Release the fuel system pressure. Section 310-00

3. Remove the muffler and tail pipe. For additional information, refer to Section 309-00 .

4. Drain the fuel tank. For additional information, refer to Section 310-00 .

All-Wheel Drive (AWD) vehicles

5. NOTE: Support the driveshaft.

   Remove the 4 rear driveshaft center bearing bracket bolts.
   • To install, tighten to 30 Nm (22 lb-ft).

6. Remove the 2 front driveshaft center bearing bracket bolts and position aside the driveshaft, securing with mechanics wire.
   • To install, tighten to 30 Nm (22 lb-ft).

7. NOTICE: Do not reuse the bolt and washer assemblies for the rear Constant Velocity (CV) joint flange. Install new assemblies or damage to the vehicle may occur.

   NOTE: Index mark the rear driveshaft flange.

   Remove and discard the 3 Rear Drive Unit (RDU) pinion flange bolt and washer assemblies.
   • To Install, tighten to 25 Nm (18 lb-ft).

8. Separate the driveshaft CV flange from the RDU flange using a flat-blade screwdriver in the area shown.

All vehicles

9. Remove the Evaporative Emission (EVAP) canister. For additional information, refer to Section 303-13 .

10. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling. For additional information, refer to Section 310-00 .

11. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling. For additional information, refer to Section 310-00 .

12. Position the Powertrain Lift under the fuel tank.

13. Remove the 2 front fuel tank strap bolts.
    • To install, tighten to 35 Nm (26 lb-ft).

14. Release the 2 straps from the fuel tank and carefully position aside.

15. Partially lower the fuel tank enough to allow access to the fuel tank wire to the main body wiring harness electrical connector.

16. Release the 2 wire harness retainers and disconnect the fuel tank wire to the main body wire harness electrical connector.

17. Release the fresh air hose vent cap and pin-type retainer from the body.

18. Carefully lower and remove the fuel tank from the vehicle.

19. Remove and discard fuel tank strap pin-type retainers from fuel tank.

20. To install, reverse the removal procedure.