B. Replace the Fuel Tank

NOTE:
Fuel tank replacement is only required if the vehicle fails the "Smoke Test" performed in Section "A." Very few vehicles are expected to require fuel tank replacement.

WARNING:
The fuel system is under a constant pressure (even with the engine off). Before replacing the fuel tank, the fuel system pressure must be released.

1. Use the following procedure to release the fuel pressure from the fuel system:

a. Remove the fuel pump relay from the Power Distribution Center (PDC). To determine the location of the fuel pump relay, refer to the label on the underside of the PDC cover.

b. Start and run the engine until it stalls.

c. Attempt to restart the engine until it will no longer run.

d. Turn the ignition to the "OFF" position.

e. Install the fuel pump relay back into the PDC.

NOTE:
Do not turn the key to the "run" position until all repairs have been made. Turning the key to the "RUN" position will turn on the fuel pump and pressurize the fuel system.

CAUTION:
One or more Diagnostic Trouble Codes (DTC's) may have been stored in the Powertrain Control Module (PCM) due to the fuel pump relay removal. A diagnostic scan tool must be used to erase all DTC's.

2. Drain the fuel tank using the following procedure:

a. Raise the vehicle on a hoist.

b. If equipped, remove the fuel tank skid plate.

c. Thoroughly clean the area around the fuel filler fitting and rubber hose at the rear of the tank.





d. Loosen the clamp and disconnect the rubber fuel filler tube at the gas tank fitting (Figure 8).

e. Using an approved fuel storage tanker, drain the fuel tank through the fuel tube filler fitting on the fuel tank.

3. Support the fuel tank with a hydraulic transmission jack.





4. Remove the two fuel tank strap bolts and remove both tank support straps (Figure 9).

5. Carefully lower the fuel tank a few inches and disconnect the fuel pump module electrical connector located on the top of the tank.

6. Disconnect the fuel line quick connect at the fuel pump module.

7. Disconnect the Natural Vacuum Leak Detection (NVLD), On-board Refueling Vapor Recovery (ORVR), and Evaporative (EVAP) lines located at the front of the fuel tank.

8. Disconnect the NVLD electrical connector.

9. Continue to lower the tank for removal.

10. With the help of an assistant, remove the old tank from the hydraulic jack and set the tank on the floor.

11. Use the following procedure to remove the fuel pump module:





a. Note the rotational position of the module before attempting removal. An indexing arrow is located on the top of the module for this purpose (Figure 10).

b. Position Special Tool 9340 into the notches on the outside edge of the lock ring (Figure 10).

c. Install a 1/2 inch drive breaker bar to Special Tool 9340.

d. Rotate the breaker bar counter-clockwise to loosen the lock ring.

e. Remove the lock ring.

NOTE:
The module will spring up slightly when the lock ring is removed.

f. Lift the fuel pump module from the fuel tank.

CAUTION:
Be careful not to bend the float arm while removing the fuel pump module.

12. Discard the old tank using an environmentally safe method.

13. Remove the new fuel tank from its packaging.

14. Install a new seal into the fuel pump module opening.

15. Position the fuel pump module into the opening in the fuel tank.

16. Position the lock ring over the top of the fuel pump module (Figure 10).

17. Rotate the module until the embossed alignment arrow points to the center alignment mark.

NOTE:
The pump module must be indexed to prevent the fuel gauge float from contacting the side of the fuel tank. Also be sure the fuel fitting on the top of the pump module is pointing towards the driver's side of the vehicle.

18. Using Special Tool 9340 and a 1/2 inch breaker bar, tighten the lock ring (clockwise) until all seven notches have engaged (Figure 10).

19. Transfer the NVLD pump, canister and canister vent line located on the front of the old fuel tank to the new fuel tank.

20. Transfer the heat shields from the old tank to the new tank.

21. Place the fuel tank assembly onto the hydraulic jack.

22. Carefully raise the tank until positioned near the body.

23. Connect the EVAP, ORVR and NVLD hoses and electrical connector located at the front of the tank.

24. Connect the fuel pump module electrical connector located at the top of the tank.

25. Connect the fuel line quick-connect fitting to the pump module.

26. Connect the fuel fill tube while raising the fuel tank into position. Continue raising the fuel tank until it is positioned snug against the floor pan.

27. Install and position both fuel tank support straps (Figure 9).

28. Install the fuel tank strap retaining bolts and tighten bolts to 30 ft. lbs. (41 N.m).

29. Position and tighten the fuel filler tube hose clamps (Figure 8).

30. Connect the fuel tank vent hose located next to the fuel fill tube (Figure 8).

31. If equipped, install the fuel tank skid plate. Tighten the bolts to 30 ft. lbs. (41 N.m).

32. Lower the vehicle and refill the fuel tank with the fuel that was removed.

33. Start the engine and check for leaks at the fuel tank and pump module area.

34. Connect the StarSCAN diagnostic tool and check all modules for Diagnostic Trouble Codes (DTC's).

NOTE:
When the fuel pump relay was removed to release the fuel system pressure, a Diagnostic Trouble Code (DTC) may have been set. Some DTC's may cause the Malfunction Indicator Lamp to illuminate. Check all modules using "System View" from the "Home" screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the Powertrain Control Module only after all other modules have had their DTC's erased.