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.

Fuel level in tank below 3/4: fuel tank draining is not necessary for tank removal.

Fuel level in tank above 3/4: the electric fuel pump may be activated allowing tank to be partially drained at fuel rail connection. Refer to DRB Scan Tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, remove gas cap and 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. Note: A temporary adapter fitting such as SnapOn tool number FIA61O may be used to attach the disconnected fuel line to the approved gasoline draining station. Activate fuel pump with DRB and drain approximately 4-5 gallons of fuel before tank removal. The fuel tank does not need to be completely emptied before removal.

Electric fuel pump not operating, and fuel level in tank above 3/4: the fuel tank does not need to be completely emptied before removal. Before disconnecting fuel line at fuel rail, remove gas cap and release fuel pressure. Attach an approved, suction- type gasoline draining station to disconnected fuel line at fuel rail. Drain approximately 4-5 gallons of fuel before tank removal. Note: A temporary adapter fitting such as SnapOn(R) tool number FIA61O may be used to attach the disconnected fuel line to the approved gasoline draining station.

1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure.
2. Disconnect negative battery cable at battery.
3. Raise and support vehicle.
4. Remove left rear wheel/tire.

Top Of Fuel Tank:

CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR/VACUUM LINES VERY CAREFULLY. THESE LINES AND HOSES MUST BE FIRMLY CONNECTED.CHECK THE VAPOR/VACUUM LINES AT THE LDP,LDP FILTER, EVAP CANISTER, EVAP CANISTER PURGE SOLENOID AND ORVR COMPONENTS FOR DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.

Stone Shield:

5. Remove stone shield behind left/rear wheel. Drill out plastic rivets for removal.

Lop Mounting Bolts:

6. Remove 3 LDP mounting bolts.

Two-Piece Support Bracket:

7. Remove support bracket brace bolt.
8 Loosen, but do not remove 2 support bracket nuts at frame rail.

LDP Removal/Installation:

9. To separate and lower front section of two-piece support bracket, remove 3 attaching bolts on bottom of support bracket. While lowering support bracket, disconnect LDP wiring clip.

Fuel Fill Tube/House/Clamp:

10. Remove hose clamp and remove fuel fill hose from fuel fill tube.
11. Cut and discard tie wrap from axle vent hose.
12. Disconnect fuel vent hose from fuel vent tube.

ORVR Hose Elbow:

13. Disconnect ORVR hose elbow at top of EVAP canister.
14. Place hydraulic jack to bottom of fuel tank.

Bumper Fascia Clips:

15. Remove fuel tank-to-rear bumper fascia clips.

Fuel Tank Heat Shield Bolts:

16. Remove fuel tank heat shield mounting bolts.

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.

Fuel Filter/Fuel Pressure Regulator:

17. Disconnect fuel return line at fuel filter/fuel pressure regulator. Refer to Quick-Connect Fittings for procedures.
18. Disconnect fuel pressure line at fuel filter/fuel pressure regulator. Refer to Quick-Connect Fittings for procedures.
19. Disconnect EVAP canister vent line near front of tank.
20. Disconnect fuel pump module electrical connector (pigtail harness) near front of tank. Harness connector is clipped to body

Bracket, Tank Support - Front:

21. Remove left I front tank support bracket bolt at frame.

Bracket, Tank Support - Rear:

Fuel Tank Mounting - No Trailer Hitch:

22. WITHOUT TRAILER HITCH: Remove tank- to-frame mounting bolts. Remove rear tank support bracket bolt at frame. Carefully lower tank until clear of vehicle. Place tank on floor.

Fuel Tank Mounting - With Trailer Hitch:

23. WITH TRAILER HITCH: Remove tank I hitch mounting bolts. Carefully lower tank until clear of vehicle. Place tank on floor.
24. If necessary, separate skid plate from fuel tank by removing 2 fuel tank strap nuts and remove 2 tank straps.
25. If fuel pump module removal is necessary refer to Fuel Pump Module Removal/Installation.
26. 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.

Fuel Filler Tube:

27. If necessary, remove 3 fuel filler tube assembly mounting bolts and remove fuel filler tube.

INSTALLATION

CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR/VACUUM LINES VERY CAREFULLY. THESE LINES AND HOSES MUST BE FIRMLY CONNECTED.CHECK THE VAPOR/VACUUM LINES AT THE LDP,LDP FILTER, EVAP CANISTER, EVAP CANISTER PURGE SOLENOID AND ORVR COMPONENTS FOR DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.

1. If necessary position fuel filler tube assembly to body. Install 3 bolts. Refer to Torque Specifications.
2. If necessary, connect quick-connect fittings to fuel pump module.
3. If fuel pump module is being installed, refer to Fuel Pump Module Removal/Installation.
4. 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.
5. Install hose clamps to hoses. Refer to Torque Specifications.
6. If necessary, position fuel tank into skid plate. Install 2 tank straps and 2 strap nuts. Refer to Torque Specifications.
7. Position fuel tank / skid plate assembly to hydraulic jack.
8. Raise tank into position to frame.
9. WITH TRAILER HITCH: Position trailer hitch and tow hooks to bottom of fuel tank. Install bolts and nuts loosely
10. WITHOUT TRAILER HITCH: Install 2 rear tank support brackets and bolts. Install tank-to-frame bolts. Do not tighten bolts I nuts at this time.
11. Install 1 left I front tank support bracket and bolts I nuts. Do not tighten bolts I nuts at this time.
12. Be sure fuel tank is properly aligned to frame and body. Tighten all tank, tow hook and trailer hitch bolts I nuts except for 3 support brackets. Tighten all 3 (2 rear and 1 left I front) support bracket bolts I nuts last. Refer to Torque Specifications.
13. Connect fuel pump module pigtail harness electrical connector near front of tank.
14. Connect both fuel lines to fuel filter/fuel pressure regulator. Refer to Quick-Connect Fittings for procedures.
15. Connect EVAP hose near front of tank.
16. Position rear axle vent hose and install new tie strap.
17. Install heat shield nuts I bolts. Refer to Torque Specifications.
18. Connect ORVR hose elbow to top of EVAP canister.
19. Connect fuel vent hose to fuel vent tube.
20. Install fuel fill hose and clamp to fuel fill tube.
21. Install 3 LDP mounting bolts.
22. While raising support bracket, connect LDP wiring clip. Install front section of two-piece support bracket to rear section with 3 attaching bolts located on bottom of support bracket.
23. Install support bracket brace bolt.
24. Tighten 2 support bracket nuts at frame rail.
25. Install fuel tank-to-rear bumper fascia clips.
26. Using new plastic rivets, install stone shield behind left/rear wheel.
27. Install left rear wheel/tire.
28. Lower vehicle and connect negative battery cable to battery.
29. Fill tank with fuel and check for leaks.