Fuel Tank: Service and Repair

REMOVAL

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

Two different procedures may be used to drain fuel tank (through tank vent fitting or using DRB scan tool). The quickest is draining through tank vent fitting.

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 for procedures. Attach end of Special Adapter Hose Tool number 6539 at fuel rail disconnection. Position opposite end of 6539 to an approved gasoline draining station. Activate fuel pump with DRB and drain tank until empty.

If electric fuel pump is not operating, tank MUST be drained through vent fitting.
1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure.
2. Disconnect negative battery cable at battery.
3. Raise and support vehicle.

Fig.27 Fuel Tank Assembly (Top View):

4. Working from front of fuel tank, loosen clamp at fuel vent hose at fuel tank end of hose (Fig. 27). Remove hose at tank fitting.
5. Obtain a length of 3/8" O.D. thinwall, clear tubing.
6. Position 3/8" O.D. tubing into tank vent fitting. Attach 3/8" tubing to an approved gasoline draining station. Drain tank until empty.
7. Remove rear tow hooks (if equipped).
8. Remove optional trailer hitch (if equipped).

Fig.28 Fuel Tank-To-Rear Bumper Fascia Clips:

9. Remove fuel tank-to-rear bumper fascia clips (Fig. 28).

Fig.29 Fuel Tank Heat Shield Bolts:

10. Remove fuel tank heat shield mounting bolts (Fig. 29).

CAUTION: To protect fuel tank from exhaust heat, shield must re-installed after tank Installation.

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

Fig.30 Fuel Filter/Fuel Pressure Regulator:

11. Disconnect fuel return line at fuel filter/fuel pressure regulator (Fig. 30). Refer to Quick-Connect Fittings for procedures.
12. Disconnect fuel pressure line at fuel filter/fuel pressure regulator (Fig. 30). Refer to Quick-Connect Fittings for procedures.
13. Disconnect EVAP canister vent line near front of tank (Fig. 30).
14. Disconnect fuel pump module electrical connector (pigtail harness) near front of tank (Fig. 30). Harness connector is clipped to body.

Fig.31 Fill And Vent Hoses:

15. Cut and discard tie strap supporting rear axle vent hose to tank vent hose (Fig. 31).
16. Remove clamp on axle vent hose at rear axle.
17. Remove vent hose from fitting at rear axle.
18. Loosen fill and vent hose clamps at body (Fig. 31). Disconnect fill and vent hoses at filler tube assembly.
19. Place hydraulic jack to bottom of fuel tank.

Fig.32 Fuel Tank Mounting:

20. Remove tank-to-frame mounting bolts (Fig. 32).
21. Carefully lower tank until clear of vehicle. Place tank on floor.
22. If necessary, remove two fuel tank strap nuts (Fig. 32).
23. If fuel pump module removal is necessary; refer to Fuel Pump Module Removal/Installation.
24. If hoses are to be removed at fuel tank end, note painted alignment (indexing) markings on hoses, and molded indexing tangs on tank before removal. Remove hoses.

Fig.33 Fuel Filler Tube:

25. If necessary, remove 3 fuel filler tube assembly mounting bolts (Fig. 33) and remove fuel filler tube.

INSTALLATION
1. If fuel pump module is being installed, refer to Fuel Pump Module Removal/Installation.
2. If necessary, position fuel filler tube assembly to body. Install 3 bolts and tighten to 2 Nm (15 in. Lbs.) torque.
3. Install fuel fill/vent hoses to tank fittings. To prevent hoses from kinking, rotate each hose until painted indexing mark on hose is aligned to molded indexing tang on tank.
4. Install hose clamps to hoses. Tighten clamp screws to 3 Nm (25 in. Lbs.) torque.
5. Position fuel tank to hydraulic jack.
6. Raise tank into position.
7. Install fuel tank mounting bolts. Tighten bolts to 81 Nm (60 ft. Lbs.) torque.
8. Install fuel fill and vent hoses to fuel fill tube at body. Install clamps and tighten clamp screws to 3 Nm (25 in. Lbs.) torque.
9. Connect fuel pump module pigtail harness electrical connector near front of tank.
10. Connect both fuel lines to fuel filter/fuel pressure regulator. Refer to Quick-Connect Fittings for procedures.
11. Connect EVAP hose near front of tank.
12. Position rear axle vent hose and install new tie strap.
13. Install new clamp to rear axle vent hose.
14. Install vent hose to fitting at rear axle and tighten clamp.
15. Install heat shield bolts.
16. Install trailer hitch (if equipped).
17. Install rear tow hooks (if equipped).
18. Install fuel tank-to-rear bumper fascia clips.
19. Lower vehicle and connect negative battery cable to battery.
20. Check for leaks.