Removal procedure
Attention! Do not smoke or use open flames in areas where fuel is handled or on the EMS system (gasoline vapor recovery system). When working on the fuel system, disconnect the negative battery cable, except for tests that require battery voltage.
Attention! The fuel system is under pressure. Depressurize the fuel supply system before disconnecting fuel lines to prevent fuel spillage and burns.
1. Disconnect the negative battery cable.
2. Drain fuel from tank. Ensure the fuel level in the tank is less than 1/4 full. If necessary, empty the fuel tank to at least this level.
3. Relieve pressure in the fuel supply system. See «Relieving pressure in the fuel supply system» in this section.
4. Raise and support the vehicle.
5. Remove the front muffler. See Part 1G3, Exhaust System - HFV6 3.2L.
6. Remove impeller shaft and rear drive module (RDM). See Part 3B, Rear Drive Axle
7. Disconnect the fuel pump connector on the right side of the fuel tank.
8. Disconnect the filler neck pipe, the vent hose of the gasoline vapor recovery system from the fuel tank (SUPS) and a vapor hose.
9. Disconnect the fuel line located near the right front side of the fuel tank.
10. Disconnect the fuel vapor pipe from the canister of the gasoline vapor recovery system (SUPS).
11. Support the fuel tank.
12. Remove the parking brake cable support bracket bolts and move them away from the fuel tank.
13. Remove the fuel tank clamp mounting screws.
14. Remove fuel tank straps.
15. Gently push and move the front of the fuel pump down while tilting the rear of the fuel pump up.
16. Remove fuel tank.
Installation procedure
1. Install the fuel tank in its original position.
2. Install the fuel tank clamps.
Tighten
Tighten the fixing screws of the fuel tank clamps to 20 Nm (15 lb-ft).
3. Install the parking brake cable support bracket bolts.
4. Connect the fuel vapor pipe to the canister of the gasoline vapor recovery system (SUPS).
5. Connect the fuel line near the right front side of the fuel tank.
6. Connect the fuel filler pipe, EVAP purge hose (SUPS) and a vapor hose.
7. Connect the fuel pump connector on the right rear side of the fuel tank.
8. Install the parking brake cable support brackets. See Section 4G, Parking brake.
9. Install the front muffler. See Part 1G3, Exhaust System - HFV6 3.2L.
10. Install impeller shaft and RDM. See Part 3B, Rear Drive Axle
11. Fill up the fuel tank.
12. Connect the negative battery cable.
13. Check for leaks at fuel tank and fuel line connections.
