Orlando

Fuel Tank Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Open the bonnet.
2. Disconnect the battery negative cable. Refer to  Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .




Warning: Do not breathe the air through the EVAP component tubes or hoses. The fuel vapours inside the EVAP components may cause personal injury.

Warning: Petrol or petrol vapours are highly flammable. A fire could occur if an ignition source is present. Never drain or store petrol or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

5. Unclip the fuel feed pipe (3) from the rear bracket clip (2).
6. Disconnect the fuel tank feed pipe connector (1) from the fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
7. Close the fuel feed pipe and the fuel tank feed pipe with EN-6015 closure plugs .



8. Unclip the fuel vent pipe (3) from the rear bracket clip (2).
9. Disconnect the evaporative emission canister fuel vent pipe connector (1) from the fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
10. Close the fuel tank vent pipe and emission canister fuel vent pipe with EN-6015 closure plugs .



11. Remove the clamp (2).
12. Remove the fuel tank filler hose (3) from the fuel tank filler pipe (1).
13. Disconnect the fuel tank filler vent pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .




Caution: When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.

14. Place a suitable adjustable jack under the fuel tank (1).
15. Remove the 2 fuel tank strap bolts (3) with the fuel tank strap bolt retainers (2).
16. Remove the 2 fuel tank strap bolts (5) with the fuel tank strap bolt retainers (6).
17. Demount the 2 fuel tank straps (4).




Note: A second technician is required.

18. Lower the jack stepwise, until you can remove the fuel tank fuel pump module wiring harness plug (2).
19. Disconnect the fuel tank fuel pump module wiring harness plug (2) from the fuel tank fuel pump module (1).
20. Unclip the fuel tank fuel pump module wiring harness from the 2 bracket clips (3).

Note: Lower the jack.

21. Remove the fuel tank.

1. Remove the fuel tank heat shield. Refer to  Fuel Tank Heat Shield Replacement : 2.4L LAF → 2.0L Diesel LNP .
2. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement .




Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

3. Disconnect the fuel tank vent pipe (2).
4. Close the fuel tank vent pipe (2) with the CH-807 plug .
5. Disconnect the evaporative emission canister purge pipe (4).
6. Remove the evaporative emission canister (1) from the evaporative emission canister bracket (3).

1. Install the evaporative emission canister (1) to the evaporative emission canister bracket (3).
2. Connect the evaporative emission canister purge pipe (4).
3. Remove the CH-807 plug from the fuel tank vent pipe.
4. Connect the fuel tank vent pipe (2).
5. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement .
6. Install the fuel tank heat shield. Refer to  Fuel Tank Heat Shield Replacement : 2.4L LAF → 2.0L Diesel LNP .

Note: A second technician is required.

1. Raise the jack stepwise, until you can install the fuel tank fuel pump module wiring harness plug (2).
2. Connect the fuel tank fuel pump module wiring harness plug (2) to the fuel tank fuel pump module (1).
3. Clip the fuel tank fuel pump module wiring harness to the 2 bracket clips (3).

Note: Raise the jack.

4. Install the fuel tank.



5. Pre-install the 4 fuel tank strap bolts (3, 5) with the 4 fuel tank strap bolt retainers (2, 6) at the fuel tank straps (4).
6. Mount the 2 fuel tank straps (4).

Caution: Refer to Fastener Caution in the Preface section.

7. Install the 4 fuel tank strap bolts (3, 5) and tighten to 20 N·m (15 lb ft).



8. Remove the EN-6015 closure plugs from the emission canister fuel vent pipe and the fuel tank vent pipe.
9. Connect the emission canister fuel vent pipe (1) to the fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
10. Clip the fuel vent pipe (3) into the rear bracket clip (2).



11. Remove the EN-6015 closure plugs from the fuel feed tank pipe and the fuel feed pipe.
12. Connect the fuel tank feed pipe connector (1) to the fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
13. Clip the fuel feed pipe (3) into the rear bracket clip (2).



14. Connect the fuel tank filler vent pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
15. Install the fuel tank filler hose (3) to the fuel tank filler pipe (1).
16. Install the clamp (2).
17. Lower the vehicle.
18. Connect the battery negative cable. Refer to  Battery Negative Cable Disconnection and Connection : without Start/Stop System .
19. Close the bonnet.