Rear Rack Assembly

FUEL TANK - REAR RACK ASSEMBLY

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL

WARNING:
- The status (stuck open, normal operation, stuck closed or does not operate) of each fuel tank solenoid valve must be identified prior to venting the fuel system. Refer to Diagnosis and Testing. Venting of the fuel system without identifying solenoid status could result in an unexpected release of natural gas into the atmosphere, possibly resulting in injury or property damage.
- Eye protection is required when removing or installing fuel system components to avoid possible injury.

1. Carry out Pressure Relief-Fuel System.
2. Disconnect the battery ground cable.







3. Remove the rear fuel tank rack decor panel.







4. Remove the luggage compartment trim panel.







5. Remove the luggage compartment weatherstrip.







6. NOTE: Tank package removed for clarity.

Remove the rear upper tank package vent box cover.







7. Remove the 12 bolts and the vapor box cover.







8. Disconnect the solenoid valve electrical connector.







9. Remove the fuel vapor tube.







10. Pull the wiring harness through the pass-through.







11. Disconnect the fuel vapor tube.







12. Disconnect and remove the fuel vapor tube.







13. Detach the pass-through tube and push it forward to the No. 1-2 tank package vapor box.







14. NOTE: The bolts are under the tank.

Remove the six tank package-to-tank package bolts.







15. Install the special tool.







16. NOTE: The tank package is removed for clarity.

Install the safety chains.







17. Remove the nuts and bolts from the support legs.







18. Remove the two upper bolts.
19. Using the Powertrain Lift, remove the rear fuel tank rack assembly from the vehicle.

INSTALLATION

1. NOTE:
- Install clean new O-ring seals in the fuel line connections. Natural gas approved O-ring seals are identified with a yellow stripe. Do not use unapproved O-ring seal.
- Lubricate the fuel line O-ring seals with clean engine oil prior to installation to help seal and ease installation.
- When tightening the fuel tube, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the wrench being used. To correct the effective torque, a torque multiplication conversion must be used.
- Be careful to position the fuel line tube and wiring harness through the body access hole.

Using the special tool and the Powertrain Lift, position the fuel tank into the vehicle.







2. Install the upper tank package bolts.







3. Install the four lower support bolts.







4. Remove the safety chains from the tank package.
5. Remove the special tool from the vehicle.







6. Install the six lower tank package-to-tank package bolts under the tank.







7. Install the trunk weatherstrip.







8. Install the luggage compartment trim panel.







9. Install the crossover tube.







10. Install the fuel tube to the "T" fitting.







11. Install the fuel tube.







12. Pull the electrical connectors through the crossover tube into the No. 3 vapor box.







13. Install the fuel tube.







14. Connect the solenoid valve electrical connector.







15. Install the No. 3 vapor box cover.







16. Install the upper No. 1-2 tank vapor box cover.
17. Connect the battery ground cable.







18. Install the rear tank rack decor panel and retain with the pin-type retainers.
19. Pressurize the fuel system.
1 Turn the jack screws counterclockwise until resistance is felt.
2 Turn the ignition switch to the RUN position.