Removal and Replacement

Fuel Tank Replacement

Special Tools

* EN-48536 - Frame Support Tool (Engine Lower 65 mm Kit)

* 7371 - Quick Connect Release Tool

* 7370 - Fuel Line Quick Connect Separator

Removal Procedure

1. Ignition OFF.

Warning:
Refer to Battery Disconnect Warning Battery Disconnect Warning.


2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.


3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

Warning:
Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


4. Relieve the low side fuel pressure. Refer to Fuel Pressure Relief (High Pressure) Fuel Pressure Relief (High Pressure)Fuel Pressure Relief (Low Pressure) Fuel Pressure Relief (Low Pressure).

5. Drain the fuel tank. Refer to Fuel Tank Draining Procedures.

6. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation Service and Repair.

7. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement Service and Repair.

8. Remove the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) Propeller Shaft Replacement (Except 4L60).

9. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement Fuel Tank Heat Shield Replacement.

10. Remove the parking brake rear cables. Refer to Parking Brake Rear Cable Replacement (9C3) Parking Brake Rear Cable Replacement (9C3)Parking Brake Rear Cable Replacement (9C1) Parking Brake Rear Cable Replacement (9C1).

11. Remove the rear stabilizer bar. Refer to Stabilizer Shaft Replacement Rear Suspension.

12. Disconnect the fuel feed line pressure sensor connector. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe Fuel Pressure Sensor Replacement - Fuel Feed Pipe.





13. Disconnect the EVAP pipe (1) from the fuel tank filler vent pipe.

14. Loosen the filler tube clamp (1) at the filler tube.





15. Using the 7370 - separator remove the EVAP pipe (2) from the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

16. Using the 7371 - tool remove the fuel feed pipe (1) from the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service Procedures.





17. Disconnect the fuel tank assembly electrical connector (1) from the chassis electrical harness.





18. Support the rear frame assembly (1) using a suitable tool (2).





Note:
The rear frame to chassis retaining bolts are single use items and must be replaced with NEW bolts.

19. Remove the rear frame to chassis retaining bolts (1) and discard.

20. Remove the rear frame to chassis retaining bolts (2) and discard.





Note:
Make sure that the EN-48536 - tool bolts (2) extends 50 mm (2 in) from the rear frame.

21. Install the EN-48536 - tool to the rear frame mounts (1).

Note:
When lowering the rear frame do not to damage the rear brake hoses.

22. Lower the rear frame onto the frame support tool EN-48536 (2).





23. Remove the EVAP emission hoses from the EVAP emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





Note:
Do not to damage the following components when lowering the fuel tank assembly.

* The fuel tank assembly wiring harness.

* The fuel feed pipe.

* The EVAP pipes.

Note:
Support the fuel tank assembly while removing the fuel tank assembly retaining straps to chassis retaining bolts (1)

24. Remove the fuel tank assembly retaining straps to chassis retaining bolts (1).

25. With the aid of an assistant, carefully manoeuvre the fuel tank assembly from the vehicle.

26. If the fuel tank is to be replaced, remove the following components.

* The fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement - Right Side Fuel Tank Fuel Pump Module Replacement - Right Side.

* The fuel tank pressure sensor. Refer to Fuel Tank Pressure Sensor Replacement Service and Repair.

* The fuel feed pipe pressure sensor. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe Fuel Pressure Sensor Replacement - Fuel Feed Pipe.

* Fuel tank electrical harness.

* EVAP pipes.

Installation Procedure





1. If the fuel tank was replaced, install the following components.

* The fuel feed pipe pressure sensor. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe Fuel Pressure Sensor Replacement - Fuel Feed Pipe.

* The fuel tank pressure sensor. Refer to Fuel Tank Pressure Sensor Replacement Service and Repair.

* The fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement - Right Side Fuel Tank Fuel Pump Module Replacement - Right Side.

* The fuel tank assembly electrical harness.

* The fuel tank EVAP pipes.

Note:

* Do not to damage the following components when installing the fuel tank assembly:

- The fuel tank assembly wiring harness.

- The fuel tank assembly electrical harness.

- The fuel tank EVAP pipes.

* Support the fuel tank assembly while installing the fuel tank assembly retaining straps to chassis retaining bolts (1).

2. With the aid of an assistant install the fuel tank assembly to the vehicle.

3. Install the fuel tank assembly retaining straps.

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the fuel tank assembly strap to chassis retaining bolts (1) and tighten to 30 Nm (22 lb ft).





Note:
Listen for an audible click to confirm correct installation of the EVAP emission hoses.

5. Connect the EVAP emission hoses to the EVAP emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





6. Raise and support the rear frame assembly (1) into its position using a suitable tool (2).





7. Remove the EN-48536 - tool(2) from the rear frame mounts (1).





8. Using a suitable tool clean the threaded holes (1 and 2) in the rear frame.

9. Install NEW rear frame to chassis retaining bolts (2).

Do not fully tighten at this stage.

10. Install NEW rear frame to chassis retaining bolts (1).

Do not fully tighten at this stage.

11. Tighten the NEW rear frame to chassis retaining bolts (1) and (2).

1. First Pass: Tighten the bolts to 65 Nm (48 lb ft).

2. Final Pass: Tighten the bolts a further 125 degrees.





Note:
Listen for an audible click to confirm correct installation of the fuel tank electrical connector.

12. Connect the fuel tank assembly electrical connector (1) to the chassis electrical harness.





Note:
Listen for an audible click to confirm correct installation of the EVAP pipe (2) and the fuel feed pipe (1).

13. Connect the EVAP pipe (2) to the EVAP chassis pipe.

14. Connect the fuel feed pipe (1) to the chassis fuel feed pipe.





15. Install the filler tube clamp (1) to the fuel tank assembly. Tighten the filler tube hose clamp (1) to 4 Nm (35 lb in).

Note:
Listen for an audible click to confirm correct installation of the EVAP hose (1).

16. Install the EVAP pipe (1) to the fuel vent pipe.

17. Connect the fuel feed line pressure sensor. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe Fuel Pressure Sensor Replacement - Fuel Feed Pipe.

18. Install the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement Fuel Tank Heat Shield Replacement.

19. Install the parking brake rear cables. Refer to Parking Brake Rear Cable Replacement (9C3) Parking Brake Rear Cable Replacement (9C3)Parking Brake Rear Cable Replacement (9C1) Parking Brake Rear Cable Replacement (9C1).

20. Install the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) Propeller Shaft Replacement (Except 4L60).

21. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement Service and Repair.

22. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation Service and Repair.

23. Lower the vehicle.

24. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

25. Inspect for fuel leaks using the following procedure:

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

2. Turn OFF the ignition, for 10 seconds.

3. Turn ON the ignition, with the engine OFF.

4. Inspect for leaks.