Complete removal and replacement of the fuel tank assembly, including disconnecting fuel lines, electrical connections, and removing tank mounting straps.

Warnings

Tools required

Parts

• Fuel tank assembly × 1 — Use OEM specification
• Fuel tank cushion/insulator set × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification
• Filler neck hose clamp × 1 — Use OEM specification
• Fuel pump assembly gasket × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground in well-ventilated area away from all ignition sources
2. Place Class B fire extinguisher within immediate reach
3. Allow engine to cool completely (minimum 2 hours if recently operated)
4. Disconnect negative battery cable and isolate terminal to prevent sparks
5. Remove fuel pump relay (located in engine compartment fuse box, position #19) and start engine to consume remaining fuel in lines until engine stalls
6. Attempt to start engine 2-3 more times to ensure fuel pressure is relieved
7. Calculate fuel quantity: tank capacity is 13.2 gallons. If more than 5 gallons present, siphon fuel into approved fuel storage containers using manual pump (never by mouth)
8. Raise vehicle on lift or securely support on jack stands at all four corners - minimum 18 inches clearance needed
9. Remove rear seat cushion by releasing two clips at front edge and lifting upward
10. Remove fuel pump access cover screws and cover plate to access fuel pump electrical connector

Procedure

1. 1

   Disconnect fuel pump electrical connector
   Disconnect the fuel pump electrical connector located under the rear seat access panel. Press the release tab and pull connector straight out. Label connector orientation if needed for reassembly.
   ⚠Ensure battery is disconnected before handling electrical connections to prevent sparks near fuel vapors.
2. 2

   Remove exhaust system hanger
   Locate the rear exhaust hanger approximately 12 inches forward of the rear bumper. Support exhaust with jack stand. Remove rubber hanger and lower exhaust system approximately 3-4 inches to provide clearance for tank removal. Do not disconnect exhaust pipes.
3. 3

   Disconnect fuel filler neck
   Locate fuel filler neck connection on driver side of tank. Loosen the hose clamp using flathead screwdriver or socket. Twist and pull filler neck hose off the tank inlet pipe. Allow any residual fuel to drain into drain pan.
   ⚠Fuel will spill from filler neck. Position drain pan to capture all fuel.
4. 4

   Disconnect fuel tank breather hose
   Locate the EVAP breather hose on the passenger side of the tank near the filler neck. Press the quick-disconnect release tabs and pull hose straight off. Cap or plug the hose end to prevent contamination.
5. 5

   Disconnect fuel supply and return lines
   Using appropriate fuel line disconnect tool, disconnect the fuel supply line and return line at the front of the fuel tank. Press tool onto fitting, push toward tank, and pull line out. Have shop towels ready to catch fuel spillage. Inspect O-rings and discard - new O-rings must be installed during reassembly.
   ⚠Fuel will spray when lines are disconnected. Wear safety goggles and have towels ready to absorb spilled fuel.
6. 6

   Disconnect EVAP vapor line
   Locate EVAP canister vapor line on passenger side of tank. Press quick-disconnect tabs and remove line from tank connection. Label line routing if necessary for reinstallation.
7. 7

   Support fuel tank
   Position transmission jack or dedicated fuel tank support stand under the center of the fuel tank. Raise jack until it just contacts tank bottom with light pressure. Secure tank to jack with strap or adjustable support arms to prevent shifting during removal.
   ⚠️Tank will become unstable when straps are removed. Ensure jack is positioned securely at tank center of gravity and strap is secured before loosening tank straps.
8. 8

   Remove fuel tank strap bolts
   Locate the two fuel tank strap bolts at the rear of each tank strap (4 bolts total). Using 14mm socket, remove all four strap mounting bolts. Support straps as you remove final bolt to prevent them from falling. Lower straps away from tank.
   ⚠Tank straps are under tension and may swing down when released. Keep hands clear of strap path.
9. 9

   Lower and remove fuel tank
   Carefully lower transmission jack approximately 6 inches. Verify all hoses, lines, and electrical connections are disconnected. If resistance is felt, stop and verify all connections are free. Continue lowering tank completely and slide tank out from under vehicle on jack. Transfer to suitable work surface.
   ⚠️Tank may still contain several gallons of fuel and is heavy. Lower slowly and maintain control at all times. Get assistance if needed.
10. 10

    Inspect and clean mounting area
    With tank removed, inspect all fuel line connections, brake lines, and underbody for damage, corrosion, or leaks. Clean tank mounting surfaces with wire brush. Inspect tank strap mounting points for rust or damage. Replace tank cushions/insulators if compressed, cracked, or deteriorated.
11. 11

    Prepare new fuel tank
    If installing new tank, transfer fuel pump assembly, fuel level sender, and all fittings from old tank to new tank. Install new fuel pump gasket. Verify all threaded connections are tight. Install new tank cushions/insulators in correct positions matching original locations.
12. 12

    Position and raise fuel tank
    Place fuel tank on transmission jack. Align tank orientation (filler neck side toward driver side). Raise tank into position under vehicle, guiding filler neck and all lines through their respective openings. Align tank strap mounting points. Stop when tank is approximately 1 inch from final position.
13. 13

    Install tank straps and torque bolts
    Position both fuel tank straps over tank. Start all four tank strap bolts by hand. Ensure tank is centered and level. Tighten bolts in diagonal pattern (front left, rear right, front right, rear left) to ensure even pressure. Torque all four strap bolts to specification using torque wrench.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
14. 14

    Reconnect fuel lines with new O-rings
    Install new O-rings on all fuel line fittings - lubricate lightly with clean gasoline. Connect fuel supply and return lines to tank, pushing firmly until click is heard or felt. Pull back on each line to verify secure connection. Connect EVAP vapor line until it clicks into place.
    ⚠Always use new O-rings. Reusing old O-rings will cause fuel leaks and potential fire hazard.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
15. 15

    Reconnect filler neck and breather
    Connect fuel filler neck hose to tank inlet pipe, ensuring hose is fully seated. Install new clamp and tighten to specification. Connect breather hose to tank connection, pushing until it clicks. Verify both connections are secure by pulling gently on hoses.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
16. 16

    Reconnect exhaust hanger
    Raise exhaust system back to original position. Install rubber exhaust hanger. Remove support jack from exhaust. Verify exhaust has adequate clearance from tank and hangs level.
17. 17

    Reconnect fuel pump electrical connector
    Connect fuel pump electrical connector under rear seat, ensuring it clicks fully into place. Reinstall fuel pump access cover and secure with screws to specification. Reinstall rear seat cushion by engaging rear hooks and pressing down at front until clips engage.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)
18. 18

    Reconnect battery and prime fuel system
    Reconnect negative battery cable. Reinstall fuel pump relay in fuse box position #19. Turn ignition to ON position (do not start) for 5 seconds, then OFF. Repeat this cycle 4-5 times to prime fuel system and pressurize lines. Check all fuel connections for leaks while system is pressurized.
    ⚠️Inspect all fuel connections thoroughly for leaks during priming. Any fuel leak presents immediate fire hazard.

Reassembly

1. All fuel line connections must use new O-rings - never reuse old O-rings
2. Ensure all quick-disconnect fittings click audibly and are verified by pull-test
3. Tank strap bolts must be torqued in diagonal pattern to prevent tank distortion
4. Verify fuel pump electrical connector is fully seated before reinstalling access cover
5. Exhaust system must hang freely without contact to fuel tank or lines

Verification

• With ignition ON (engine not running), verify fuel pump runs for 2 seconds then stops - indicates proper electrical connection
• Inspect all fuel line connections, filler neck, and breather hose for fuel leaks while system is pressurized
• Start engine and let idle for 5 minutes, monitoring for fuel odor or visible leaks under vehicle
• With engine running, inspect all connections again from underneath vehicle using flashlight - look for wet spots or drips
• Test drive vehicle and monitor for fuel odor in cabin or check engine light
• After test drive, perform final inspection of all connections with vehicle on lift or jack stands
• If any fuel odor is detected at any point, immediately shut off engine and re-inspect all connections - do not operate vehicle until leak is found and corrected

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