Fuel Tank Removal and Installation

The content of this article reflects the changes called out by TSB 26-10-00.

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

REMOVAL
1. Release fuel system pressure.
2. Disconnect negative cable from auxiliary jumper terminal.
3. Remove lower rear seat cushion and disconnect pump wiring jumper from main body harness. Locate body grommet for jumper near base of rear seat. Push grommet out and feed jumper completely through hole in body.
4. Remove fuel cap slowly to release tank pressure.
5. With vehicle on a hoist, drain fuel from tank. Support fuel tank with a support such as a transmission jack stand.
6. Position a fuel approved container, with a capacity of at least 16 gallons, under the drain plug located on the bottom left edge of the tank.

CAUTION: Use a backup wrench on tank to remove drain plug.

Fig.28 Fuel Tank Drain Plug:

7. Remove drain plug and allow fuel to drain (Fig.28).

WARNING: DRAIN PLUG MUST BE INSTALLED AT THIS TIME AS THERE WILL BE 1 TO 2 GALLONS OF FUEL LEFT IN THE TANK.

8. When tank is no longer draining, install drain plug. Tighten plug to 32 in.lbs.

WARNING: There may be fuel in the fill tube. Remove hose carefully to reduce fuel splash.

Fig.29 Fuel Filter Hose Clamp:

9. Disconnect fuel tank from rubber fill hose (Fig. 29).

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

Fig.30 Fuel Tank Removal:

10. Disconnect fuel lines from fuel pump module. These are quick connect fittings (Fig. 30).
11. Disconnect recirculation line from tee on tank mounted rollover valve. The valve is located at the rear of the tank and connects to the vapor line with a rubber hose.
12. Remove bolts and fuel tank straps.
13. Remove vacuum line to LDP.
14. Remove tank from vehicle. Slide tank forward during removal to allow fill neck to clear suspension cross-member.

INSTALLATION
1. Position fuel tank on transmission jack.
2. Raise tank into position.
3. Connect vapor line to tee to rollover valve.
4. Install EVAP hoses and lines.
5. Connect chassis fuel tube to fuel filter. Refer to Quick Connect Fittings in the Fuel Delivery.
6. Connect fuel fill tube to tank inlet. Tighten hose clamp to 3.5 Nm (31 in. lbs.) torque.
7. Install pump module harness grommet into body.
8. Position fuel filter and fuel tank straps. Install the front bolts first and then the rear bolts. Tighten fuel tank strap bolts to 23 Nm (250 in. lbs.) torque. Remove transmission jack. Ensure straps are not twisted or bent.
9. Lower vehicle.
10. Connect fuel pump module connector.
11. Fill fuel tank, install filler cap, and connect battery cable.

CAUTION: When using the ASD Fuel System Test, the ASD relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the OFF position.

12. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.