Fuel Tank: Service and Repair

REMOVAL

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK.

Two different procedures may be used to drain fuel tank (lowering tank or using DRB scan tool).

The quickest draining procedure involves lowering the fuel tank.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail connection. Refer to DRB scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure. Attach end of special test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and drain tank until empty.

If electric fuel pump is not operating, tank must be lowered for fuel draining. Refer to following procedures.

1. Disconnect negative battery cable at battery
2. Release fuel system pressure. Refer to the Fuel System Pressure Release Procedure.
3. Raise and support vehicle.
4. If Equipped: Remove fuel tank skid plate. Refer to 23, Body for procedures.

Fig.20 Fuel Hose Shield:

5. Remove 4 fuel hose shield mounting bolts and remove fuel hose shield (Fig. 20) from body.

Fig.21 Fuel Fill And Vent Hoses:

6. Remove fuel tank fill hose and vent hose clamps at fuel tank filler tube (Fig. 21). Remove both hoses at fuel filler tube (Fig. 21).
7. Remove exhaust tailpipe heat shield mounting bolts and remove shield.

CAUTION: To protect fuel tank from exhaust heat, this shield must reinstalled after tank installation.

8. Place a hydraulic jack to bottom of fuel tank.

WARNING: PLACE A SHOP TOWEL AROUND FUEL LINES TO CATCH ANY EXCESS FUEL.

Fig.22 Fuel Tank Connections At Front of Fuel Tank:

9. Disconnect fuel supply line from fuel extension line near front of fuel tank (Fig. 22). Refer to Fuel Tubes/Lines-Hoses and Clamps. Also refer to Quick-Connect Fittings for procedures.
10. Disconnect EVAP canister vent line near front of tank (Fig. 22).
11. Disconnect fuel pump module electrical connector (pigtail harness) near front of tank (Fig. 22). Harness connector is clipped to body.

Fig.23 Fuel Tank Mounting Straps/Nuts:

12. Remove two fuel tank strap nuts (Fig. 23). Position both tank support straps away from tank.
13. Carefully lower right side of tank while feeding both fuel hoses through access hole in body. Fuel Tank Full And Not Drained Using DRB Scan Tool: To prevent fuel loss through hoses, keep left side of tank higher than right side while lowering.

Do not allow hose openings to drop lower than top of tank.

14. Continue lowering tank until clear of vehicle. Place tank on floor with left side (hose side) higher than right side.

Fig.24 Fuel Fill/Vent Hose Index Marks:

15. Drain tank by removing fuel fill hose at tank. Fuel fill hose is largest of 2 hoses (Fig. 24). Insert the drain hose (from an approved gasoline draining station) into hose opening. Drain tank until empty.
16. If fuel pump module removal is necessary, refer to Fuel Pump Module Removal/Installation for procedures.

INSTALLATION
1. If fuel pump module is being installed, refer to Fuel Pump Module Removal/Installation for procedures.
2. Install fuel fill/vent hoses to tank fittings. To prevent hose from kinking, rotate each hose until index mark on hose is aligned to index tang on fuel tank (Fig. 24).
3. Install hose clamps to hoses. Position clamps between index marks on each hose (Fig. 24).
4. Position fuel tank to hydraulic jack.
5. Raise tank into position while guiding fuel fill and vent hoses into and through access hole in body.
6. Continue raising tank until positioned to body.
7. Attach two fuel tank mounting straps and mounting nuts. Tighten nuts to 10 Nm (90 in. lbs.) torque. Do not over tighten nuts.
8. Install both fuel hoses to fuel fill tube. Tighten both retaining clamps.
9. Position fuel hose shield to body. Install and tighten 4 mounting bolts.
10. Connect fuel pump module pigtail harness electrical connector near front of tank.
11. Connect fuel pump module supply line near front of tank. Refer to Quick-Connect Fittings for procedures.
12. Connect EVAP hose near front of tank.
13. Install exhaust tailpipe heat shield.
14. Install fuel tank skid plate (if equipped).
15. Lower vehicle and connect battery cable to battery.