Complete removal and replacement of the fuel tank assembly, including disconnection of all fuel lines, electrical connectors, and support straps.

Warnings

Tools required

Parts

• Fuel tank assembly × 1 — 77001-0R080 or equivalent
• Fuel line O-rings × 4 — Use OEM specification
• Fuel filler neck grommet × 1 — Use OEM specification
• Tank strap cushions (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground in well-ventilated area away from any ignition sources, pilot lights, or sparking equipment
2. Allow engine and exhaust system to cool completely (minimum 2 hours after operation)
3. Relieve fuel system pressure by removing fuel pump relay (EFI2 relay in engine bay fuse box) and cranking engine until it stalls
4. Disconnect negative battery terminal and isolate cable away from battery post
5. Siphon or pump fuel from tank until less than 2 gallons remain (fuel is heavy and dangerous when full)
6. Transfer removed fuel to approved fuel storage containers and store in safe location away from vehicle
7. Raise vehicle on lift or jack and support securely on jack stands at manufacturer-specified lift points
8. Remove rear wheels for improved access to tank straps and mounting points
9. Place absorbent pads and drip pans under fuel tank area to catch any spillage

Procedure

1. 1

   Access and remove exhaust heat shield
   Locate the fuel tank heat shield covers above the tank. Remove the screws securing the heat shield covers and carefully lower them. These shields protect the tank from exhaust heat and must be reinstalled in correct position.
   Torque spec

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

   Disconnect fuel filler neck
   Locate the fuel filler neck connection at the left rear of the tank. Loosen the clamp securing the filler neck hose to the tank inlet pipe using appropriate socket. Carefully twist and pull the filler neck hose to separate it from the tank. Have absorbent material ready as residual fuel will drain.
   ⚠Residual fuel will spill from filler neck. Position drain pan to catch spillage.
   Torque spec

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

   Disconnect fuel supply and return lines
   Locate the fuel line quick-connect fittings on the right side of the fuel tank near the fuel pump module. Using the appropriate fuel line disconnect tool, press in the tabs and carefully disconnect each fuel line. The supply line is larger diameter. Cover disconnected lines with clean shop towels to prevent contamination. Check and note the condition of O-rings for replacement.
   ⚠Fuel will drip from lines. Have drain pan positioned under connection points. Do not use metal tools that may create sparks near fuel vapors.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
4. 4

   Disconnect EVAP and vent lines
   Locate the EVAP canister lines and vapor vent lines connected to the top front of the fuel tank. Using fuel line disconnect tools, carefully release each quick-connect fitting. Note the routing and connection points of each line for proper reassembly. Label lines if necessary to ensure correct reconnection.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
5. 5

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector and fuel level sender connector on top of the tank. Press the locking tab on each connector and carefully pull straight up to disconnect. Inspect connectors for corrosion or damage. Route wiring harness clear of tank removal path.
   ℹ️Take photos of connector positions and wire routing before disconnection to aid reassembly.
6. 6

   Position transmission jack under tank
   Position a transmission jack or suitable tank support device directly under the center of the fuel tank. Raise the jack until it just contacts the tank bottom with slight upward pressure. The tank should be stable but not bearing full weight on jack yet. Secure the tank to jack with straps or adjustable supports to prevent shifting during removal.
   ⚠️Tank must be properly secured to jack before removing support straps. Tank can shift unexpectedly and cause crushing injury if not adequately supported.
7. 7

   Remove tank support brackets
   Locate the tank mounting brackets at the front of the tank. Remove the bolts securing each bracket to the vehicle chassis using appropriate socket. Set brackets aside in organized manner for reinstallation. Once brackets are removed, the tank is supported only by the straps and jack.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Remove fuel tank strap bolts
   Locate the two fuel tank support straps that wrap around the bottom of the tank. Remove the bolts at the rear mounting point of each strap. The straps are under tension and will pivot forward once bolts are removed. Support straps as bolts are removed to prevent them from swinging down suddenly.
   ⚠Tank straps are under tension and may swing suddenly when final bolt is removed. Control strap movement to prevent damage.
   Torque spec

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

   Lower and remove fuel tank
   With all connections and supports removed, carefully lower the transmission jack in small increments. Guide the tank as it lowers to ensure it clears all remaining lines and mounting points. Watch for any forgotten connections that may still be attached. Once tank is lowered approximately 12 inches, tilt the front down slightly and continue lowering until tank can be rolled out from under vehicle. Two people may be required to safely maneuver the tank.
   ⚠️Tank may still contain residual fuel adding significant weight. Use proper lifting techniques and get assistance. Do not attempt to lift or maneuver tank alone.
10. 10

    Inspect and clean mounting area
    With tank removed, inspect all mounting surfaces, brackets, and straps for corrosion, damage, or wear. Wire brush any rust from strap mounting points and chassis contact areas. Inspect tank cushions and protective pads; replace if compressed or damaged. Check condition of heat shields and repair or replace as needed.

Reassembly

1. Install new fuel tank in reverse order of removal, ensuring all protective cushions and insulators are properly positioned
2. Replace all fuel line O-rings with new parts before reconnecting any fuel lines
3. Install tank straps and hand-tighten strap bolts before torquing to specification to ensure proper tank alignment
4. Torque all fasteners to specification in the sequence: tank strap bolts, mounting bolts, bracket bolts, fuel line fittings, then filler neck clamp
5. Verify all electrical connectors are fully seated with locking tabs engaged
6. Double-check that all fuel lines, EVAP lines, and vent lines are reconnected to correct ports
7. Ensure heat shields are reinstalled in original positions before lowering vehicle
8. After installation is complete, add 2-3 gallons of fuel to allow fuel pump to prime properly

Verification

• Reconnect negative battery terminal and reinstall fuel pump relay
• Turn ignition to ON position (do not start) and listen for fuel pump operation for 2 seconds. Repeat 3 times to prime system
• Inspect all connection points under vehicle for any fuel leaks while pump is priming
• Start engine and verify it runs smoothly without fuel delivery issues
• With engine running, inspect all fuel connections, filler neck, and tank seams for any signs of leakage
• Check fuel gauge operation to verify fuel level sender connector is properly connected
• Perform final inspection under vehicle after 24 hours of operation to confirm no delayed leaks have developed
• If any fuel odor is detected or leaks are found, immediately shut off engine and repair the leak before operating vehicle

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