Aft-of-Axle Fuel Tank

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.

NOTE: The 55 gallon aft-of-axle fuel tank is shown; the 35 gallon aft-of-axle fuel tank is similar.

1. Disconnect the battery ground cable.
2. Relieve the fuel pressure.
3. Drain the fuel from the fuel tank.
4. Raise and support the vehicle; refer to Maintenance/Service and Repair.







5. Disconnect the fuel tank filler pipe and the filler vent tube from the fuel tank.

NOTE: In this illustration, the vehicle body is shown removed for clarity.

6. Position the jack under the fuel tank.







7. Remove the bolts.







8. Remove the nuts.
9. Remove the fuel tank support straps.
10. Partially lower the fuel tank.







11. Disconnect the fuel lines from the fuel pump







12. Disconnect the fuel pump and fuel tank sending unit electrical connector.







13. Disconnect the hose(s) from the evaporative emission valve.







14. Disconnect the fuel tank pressure sensor electrical connector.
15. Lower the fuel tank.
16. If the fuel tank is being replaced, transfer the fuel pump, fuel tank sending unit, the evaporative emission valves and the fuel tank pressure sensor to the new fuel tank.

INSTALLATION












1. Follow the removal procedure in reverse order.