Fuel Tank

Complete removal and replacement of the fuel tank assembly, including disconnection of fuel lines, filler neck, and fuel pump module.

Warnings

Tools required

Parts

• Fuel tank assembly × 1 — Use OEM specification
• Fuel pump module gasket/seal × 1 — Use OEM specification
• Fuel line O-rings × 6 — Use OEM specification
• Filler neck hose clamp × 1 — Use OEM specification
• Tank strap bolts × 2 — Use OEM specification
• Fuel tank cushions/insulators × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface outdoors or in extremely well-ventilated shop area with no ignition sources present
2. Ensure fuel tank is less than 1/4 full. If not, use approved fuel transfer pump to drain into approved fuel storage containers
3. Disconnect negative battery cable and isolate terminal to prevent any electrical sparks
4. Allow exhaust system to cool completely if vehicle was recently driven (minimum 1 hour)
5. Raise vehicle on lift or use floor jack with jack stands rated for vehicle weight. Vehicle must be completely secure
6. Remove rear seat cushion by pulling up firmly on front edge to release clips, then fold forward to access fuel pump service cover
7. Wear fuel-resistant gloves and safety glasses for all fuel system work

Procedure

1. 1

   Relieve fuel system pressure
   Remove fuel pump service cover screws (4x) from under rear seat. Disconnect fuel pump electrical connector. Attempt to start engine; it should run briefly then stall. Crank engine 2-3 more times to ensure pressure is relieved. Connect fuel pressure gauge to fuel line to verify zero pressure. Reconnect fuel pump connector after pressure verification.
   ⚠️Even after relieving pressure, residual fuel will be present. Have shop towels ready to catch spillage.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Disconnect fuel pump module
   From under rear seat, use appropriate fuel line disconnect tool to disconnect the fuel supply and return quick-connect fittings at fuel pump module. Plug lines immediately with clean caps or plugs. Disconnect fuel pump electrical connector if not already done. Remove fuel pump module lock ring by tapping counterclockwise with plastic mallet and brass punch (not steel - spark hazard).
   ⚠️Never use steel tools directly on fuel pump lock ring. Use brass or plastic tools only to prevent sparks.
   ⚠Mark orientation of fuel pump module before removal for correct reinstallation.
3. 3

   Remove exhaust components
   From underneath vehicle, disconnect exhaust hangers at muffler and rear pipe to allow exhaust system to drop slightly. Support exhaust with stands or wire to prevent damage to hangers or catalytic converter. May need to remove exhaust heat shields if they interfere with tank removal.
   ⚠Exhaust components must be completely cool. Rubber hangers become brittle with age and may tear during removal.
4. 4

   Disconnect filler neck and breather hoses
   From rear wheelwell area (may require removing inner fender liner clips), locate filler neck connection to tank. Loosen filler neck hose clamp at tank. Disconnect filler neck hose from tank inlet. Disconnect evaporative emission breather hose and vent hose from tank using appropriate quick-connect tools. Cap all openings immediately.
   ⚠Fuel will drain from filler neck when disconnected. Have drain pan positioned to catch spillage.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
5. 5

   Disconnect fuel lines at tank
   Locate fuel supply and return lines at front of fuel tank. Use appropriate fuel line disconnect tools to separate quick-connect fittings. Note orientation and routing of lines for reassembly. Immediately cap or plug all open fuel line connections to prevent contamination and fuel spillage.
   ⚠️Residual fuel pressure may still exist at tank connections. Have shop towels ready and keep face clear of connection points.
6. 6

   Disconnect electrical connectors and EVAP lines
   Disconnect all remaining electrical connectors at tank (fuel level sender, fuel pump if not already done). Disconnect EVAP canister line at tank using quick-connect tool. Disconnect any remaining vent or breather lines. Label all connections if necessary for reassembly reference.
   ℹ️Take photos of all connections before disconnecting to aid in proper reassembly.
7. 7

   Position tank support
   Position transmission jack or dedicated fuel tank jack under center of fuel tank. Raise jack until it just contacts tank bottom. Secure tank to jack using straps or tank adapter to prevent shifting during removal. Tank must be firmly supported before loosening any mounting hardware.
   ⚠️Tank must be properly secured to jack. A falling tank can cause severe crush injuries or rupture, releasing fuel.
8. 8

   Remove tank strap bolts
   Locate two fuel tank strap mounting bolts at rear of tank. Using 14mm socket, remove both tank strap bolts completely. Carefully guide tank straps down and out of the way. Support tank weight entirely with jack at this point.
   ⚠Tank straps are under tension. As bolts are removed, straps will release suddenly. Keep hands clear of pinch points.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
9. 9

   Lower and remove fuel tank
   Very slowly lower transmission jack, continuously checking that no lines, hoses, or wires are still connected. If resistance is felt, STOP and check for missed connections. Lower tank approximately 6 inches and perform final verification that all connections are clear. Continue lowering tank completely and roll jack away from vehicle. Place tank on clean, level surface away from ignition sources.
   ⚠️Do not allow tank to tilt or tip during lowering. Even a nearly empty tank contains fuel vapor which is explosive.
   ⚠Have a second person assist with guiding tank during lowering to prevent snagging on chassis components.
10. 10

    Inspect and prepare new tank
    Inspect tank mounting points on chassis for damage or corrosion. Replace fuel tank cushions/insulators at all mounting points if worn or damaged. If reusing fuel pump module, transfer it to new tank with new gasket/seal. If installing new pump module, ensure it is properly indexed and seated before installing lock ring. Install all new O-rings on fuel line connections with light coating of clean engine oil.
    ⚠Never reuse old fuel line O-rings. Degraded O-rings will cause fuel leaks and potential fire.
    Torque spec

    Pump Mounting14 Nm (10 lb-ft)
11. 11

    Install fuel tank to vehicle
    Place new or serviced fuel tank on transmission jack and secure with straps. Raise tank into position, ensuring proper alignment with mounting points and that no wires or lines are pinched. Install tank cushions if not already in place. Guide tank up to final position, aligning strap mounting holes. Install tank straps and start both strap bolts by hand. Torque tank strap bolts to specification in alternating pattern.
    ⚠Do not fully tighten one strap bolt before starting the other. Alternate tightening to ensure even tank seating.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect fuel lines and filler neck
    Connect fuel supply and return lines at front of tank, ensuring quick-connect fittings fully engage with audible click. Tug on lines to verify secure connection. Install all new O-rings on threaded fuel line fittings and torque to specification. Connect filler neck hose to tank inlet and install new clamp, torque to specification. Connect all EVAP lines ensuring proper engagement of quick-connect fittings.
    ⚠️Verify each fuel line connection is fully engaged. Incomplete connections will leak fuel during operation.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)

    Filler Neck Clamp4 Nm (3 lb-ft)
13. 13

    Reconnect electrical connections and exhaust
    Reconnect all electrical connectors to fuel pump module, fuel level sender, and any other tank-mounted components. Ensure connectors fully seat with audible click. Reinstall exhaust hangers and verify exhaust system has adequate clearance from fuel tank with no contact points. Reinstall any heat shields removed earlier.
    ⚠Verify no exhaust components contact fuel tank or fuel lines. Heat from exhaust can damage tank or cause fuel vapor ignition.
14. 14

    Complete underbody work
    Perform final inspection of all fuel line connections, electrical connectors, and mounting hardware from under vehicle. Verify fuel tank straps are properly seated and torqued. Check that no tools or parts were left in area. Reinstall any wheel well liners or underbody panels removed for access.
    ℹ️This is final opportunity to verify all connections before adding fuel. Take time for thorough inspection.
15. 15

    Reconnect fuel pump module from cabin
    From under rear seat, reconnect fuel pump electrical connector. Install fuel pump service cover with new gasket if equipped and torque cover screws to specification. Reinstall rear seat cushion by engaging rear clips first, then pressing down firmly on front edge until clips engage.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Double-check all fuel line connections for proper engagement before reconnecting battery
2. All quick-connect fittings must show visible locking tabs engaged and resist pull-off force
3. Verify fuel tank is not in contact with exhaust system components at any point
4. Ensure all electrical connectors are fully seated and locked

Verification

• Reconnect negative battery cable
• Turn ignition to ON position (do not start) for 5 seconds, then OFF. Repeat 3 times to prime fuel system and pressurize lines
• Inspect all fuel connections for leaks while system is pressurized. Check filler neck, fuel lines at tank, fuel pump connections, and any threaded fittings
• Start engine and let idle. Immediately inspect all fuel system connections again for leaks with engine running
• Add fuel slowly (2-3 gallons maximum initially) at gas station and verify no leaks from filler neck or tank connections
• Road test vehicle and verify proper fuel gauge operation and no fuel odor in cabin or under vehicle
• After road test, perform final inspection of all fuel connections with vehicle on lift for any signs of seepage or leakage
• If any fuel odor is detected at any point, immediately shut off engine and locate source before continuing operation

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