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Fuel Tank

Powertrain Management › Fuel Delivery and Air Induction
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartFuel Tank
ManufacturerCHY
OEM part #68034793AA
Price$687.00

Labor

Replace2.7 hr
Warranty 0.0 hrSkill B
Procedures
Procedures7 steps
Fig. 1
Fig. 1
  1. Disconnect negative battery cable.
  2. Remove fuel fill cap.
  3. Raise and support vehicle.
  4. Remove fuel fill hose clamp (2) at rear of tank (6).
  5. Remove fuel fill hose (1) from fuel tank fitting (4).
  6. Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the opening.
  7. Drain fuel tank using an approved gasoline draining station.
Fuel Tank - Removal16 steps
⚠ WARNING
The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
  1. Remove fuel tank filler tube cap.
  2. Perform Fuel System Pressure Release Procedure.
  3. Raise and support vehicle.
  4. Disconnect fuel line quick connect fittings (1) and (2) at front of fuel tank (5).
  5. Remove fuel fill hose and clamp (6) at rear of tank.
  6. Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the opening.
  7. Disconnect vapor lines (4) and (5) at rear of tank.
  8. Remove rear propshaft.
  9. Support tank with a hydraulic jack.
  10. Loosen two nuts (3) at tank support bracket (1).
  11. Remove bolt (2) from tank support bracket (1).
  12. Remove tank mounting bolts (3) at both sides of tank.
  13. Partially lower tank to gain access to pump module electrical connector.
  14. Disconnect electrical connector at fuel pump module.
  15. Continue lowering tank for removal.
  16. If fuel tank is to be replaced, remove fuel pump module from tank.
Fuel Tank - Installation12 steps
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
  1. If fuel pump module is to be installed, install module to tank.
  2. Place tank to a hydraulic jack and raise just enough to connect fuel pump module electrical connector.
  3. Continue raising tank until snug to body.
  4. Install tank mounting bolts (3) at both sides of tank. Tighten to 61 Nm (45 ft. lbs.).
  5. Tighten two nuts (3) at tank support bracket (1) to 61 Nm (45 ft. lbs.).
  6. Install bolt (2). Tighten to 61 Nm (45 ft. lbs.).
  7. Install rear propshaft.
  8. Connect vapor lines (4) and (5) at rear of tank.
  9. Connect fuel fill hose and clamp (6) at rear of tank.
  10. Connect fuel line quick connect fittings (1) and (2) at front of fuel tank (5).
  11. Lower vehicle, fill tank with fuel and install fuel fill cap.
  12. Check for fuel leaks.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
DRAINING FUEL TANK - GAS📷 1
1. Disconnect negative battery cable. 2. Remove fuel fill cap. 3. Raise and support vehicle. 4. Remove fuel fill hose clamp (2) at rear of tank (6). 5. Remove fuel fill hose (1) from fuel tank fitting (4). 6. Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the opening. 7. Drain fuel tank using an approved gasoline, or diesel fuel draining station.
figure
TANK - FUEL📷 7

Removal

WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.
1
Remove fuel tank filler tube cap.
2
Perform FUEL SYSTEM PRESSURE RELEASE Procedure.
3
Raise and support vehicle.
4
Disconnect fuel line quick connect fittings (1) and (2) at front of fuel tank (5).
5
Remove fuel fill hose and clamp (6) at rear of tank.
6
Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the
opening.
7
Disconnect vapor lines (4) and (5) at rear of tank.
8
Remove rear propshaft.
9
Support tank with a hydraulic jack.
10
Loosen two nuts (3) at tank support bracket (1).
11
Remove bolt (2) from tank support bracket (1).
12
Remove tank mounting bolts (3) at both sides of tank.
13
Partially lower tank to gain access to pump module electrical connector.
14
Disconnect electrical connector at fuel pump module.
15
Continue lowering tank for removal.
16
If fuel tank is to be replaced, remove fuel pump module from tank.

Installation

1
If fuel pump module is to be installed, install module to tank.
2
Place tank to a hydraulic jack and raise just enough to connect fuel pump module electrical connector.
3
Continue raising tank until snug to body.
4
Install tank mounting bolts (3) at both sides of tank. Tighten to 61 N.m (45 ft. lbs.).
5
Tighten two nuts (3) at tank support bracket (1) to 61 N.m (45 ft. lbs.).
6
Install bolt (2). Tighten to 61 N.m (45 ft. lbs.).
7
Install rear propshaft.
8
Connect vapor lines (4) and (5) at rear of tank.
9
Connect fuel fill hose and clamp (6) at rear of tank.
10
Connect fuel line quick connect fittings (1) and (2) at front of fuel tank (5).
11
Lower vehicle, fill tank with fuel and install fuel fill cap.
12
Check for fuel leaks.
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STANDARD PROCEDURE - DRAINING FUEL TANK
1. Disconnect negative battery cable. 2. Remove fuel fill cap. 3. Raise and support vehicle. 4. Remove fuel fill hose clamp (2) at rear of tank (3). 5. Remove fuel fill hose (1) from fuel tank. 6. Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the opening. 7. Drain fuel tank using an approved gasoline, or diesel fuel draining station.