Fuel Tank Replacement (Rear Tank)

FUEL TANK REPLACEMENT (DUAL TANKS - REAR)

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. Remove the spare tire stowage lock cylinder.




3. Remove the spare tire.
4. 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).
5. Remove the rear exhaust insulator.




6. Remove the spare tire hoist crossmember bolts and crossmember.




7. Disconnect the EVAP canister quick connect fittings.




8. Disconnect the fuel and EVAP intermediate lines from the front tank.




9. Disconnect the fuel pressure sensor electrical connector (1).




10. Support the fuel tank with a suitable jack.
11. Remove the fuel tank strap bolts.

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

12. Remove the fuel tank straps.
13. With the aid of an assistant, lower the rear tank until the intermediate line connections can be reached.




14. Disconnect the fuel and EVAP intermediate lines from the rear tank.
15. Remove the fuel and EVAP intermediate lines.
16. Cap the fuel and EVAP lines in order to prevent possible EVAP/fuel system contamination.




17. Disconnect the sending unite electrical connector (2).
18. Completely lower the fuel tank.
19. With the aid of an assistant, remove the tank from the jack.
20. If necessary, remove the sending unit.

INSTALLATION PROCEDURE




1. If necessary, install the sending unit.
2. With the aid of an assistant, install the tank onto the jack.
3. Partially raise the fuel tank.
4. Connect the sending unit electrical connector (2).




5. Remove the caps from the fuel and EVAP lines.
6. Install the fuel and EVAP intermediate lines.
7. Connect the fuel and EVAP intermediate lines to the rear tank.




8. With the aid of an assistant, completely raise the rear tank.
9. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

10. Install the fuel tank strap bolts.

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

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




12. Connect the fuel pressure sensor electrical connector (1).




13. Connect the fuel and EVAP intermediate lines to the front tank.




14. Connect the EVAP canister quick connect fittings.




15. Install the spare tire hoist crossmember and bolts.

Tighten the bolts to 50 N.m (37 lb ft).




16. Install the rear exhaust insulator.
17. Install the spare tire.




18. Install the spare tire stowage lock cylinder.




19. Install the fuel tank filler housing.
20. Install the fuel tank filler housing to fuel tank fill pipe bolts.

Tighten the bolts to 2.3 N.m (20 lb in).




21. Install the fuel tank filler housing to body TORX(r) screws (1) and retainer (2).

Tighten the screws to 2.3 N.m (20 lb in).

22. Refill the fuel tank.
23. Install the fuel fill cap.
24. Connect the negative battery cable.
25. 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.