Fuel Tank Replacement (Front Tank)

FUEL TANK REPLACEMENT (DUAL TANKS - FRONT)

REMOVAL PROCEDURE

IMPORTANT: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Single Tank) Fuel Tank Draining Procedure (5.3L (L59) Engine) Fuel Tank Draining Procedure (Dual Tanks - Front) Fuel Tank Draining Procedure (Dual Tanks - Rear).
3. Disconnect the evaporative emission (EVAP) vent line from the fuel tank line.




4. Disconnect the vapor line (1) from the fuel tank.




5. Disconnect the fuel feed and EVAP lines from the fuel tank.




6. Open the clip on the side of the fuel tank retaining the intermediate lines.
7. Disconnect the fuel and EVAP intermediate lines from the front tank.
8. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.




9. If equipped, remove the fuel tank shield bolts.
10. If equipped, remove the fuel tank shield.




11. Using an adjustable jack, support the fuel tank.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions.

12. Remove the fuel tank strap bolts.
13. Remove the fuel tank straps.
14. With the aid of an assistant, carefully lower the fuel tank until the sending unit is accessible.




15. Disengage the connector position assurance (CPA) retainer.
16. Disconnect the sending unit electrical connector.
17. Completely lower the fuel tank.
18. Place the fuel tank in a suitable work area.
19. If necessary, remove the sending unit.

INSTALLATION PROCEDURE




1. If necessary, install the sending unit.
2. Place the fuel tank onto a suitable jack.
3. With the aid of an assistant, partially raise the fuel tank.
4. Connect the sending unit electrical connector.
5. Engage the CPA retainer.




6. With the aid of an assistant, completely raise the fuel tank.
7. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel tank strap bolts.

Tighten the bolts to 40 N.m (30 lb ft).

9. Remove the adjustable jack from under the fuel tank.




10. If equipped, install the fuel tank shield.
11. If equipped, install the fuel tank shield bolts.

Tighten the bolts to 15 N.m (11 lb ft).




12. Remove the caps from the fuel and EVAP pipes.
13. Connect the fuel and EVAP intermediate lines to the front tank.
14. Close the clip on the side of the fuel tank retaining the intermediate lines.




15. Connect the fuel feel and EVAP lines to the fuel tank.




16. Connect the vapor line (1) to the fuel tank.




17. Connect the EVAP vent line to the fuel tank.
18. Install the fuel fill hose to the fuel tank.
19. Tighten the fuel fill hose clamp at the fuel tank.

Tighten the clamp to 2.5 N.m (22 lb in).

20. Lower the vehicle.
21. Refill the fuel tank.
22. Install the fuel fill cap.
23. Connect the negative battery cable.
24. Use the following procedure in order to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.