Fuel Tank: Service and Repair

REMOVAL

WARNING: Do not smoke, 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.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

1. Depressurize fuel system.
2. Drain fuel from fuel tank.
3. Raise vehicle on hoist.
4. Loosen fuel tank filler pipe and vent hose clamps at metal lines and remove hoses.
5. Disconnect push connect fittings for rear fuel supply return and vapor tubes at fuel filter and steel line behind fuel filter.
6. Disconnect electrical connector for fuel tank wiring at LH side of fuel filter.
7. Disconnect plastic push connect fitting at right rear upper corner of fuel tank that connects the line from the evaporative emission tube shut off valve to the evaporative emissions canister.
8. Place a safety support under fuel tank and remove bolts from rear end of fuel tank support straps. The fuel tank support straps are hinged at the front end and will swing out of the way.
9. Remove fuel tank from vehicle.

INSTALLATION

Fuel Tank and Related Components:

1. Before proceeding, check fuel pump module unit for leaks. If necessary, tighten with fuel tank sender wrench.

NOTE: If fuel pump module assembly has been removed, the O-ring seal must be replaced.

2. Place fuel tank in its proper position in vehicle.
3. Connect plastic push connect fitting at right rear corner of fuel tank.
4. Connect electrical connector for fuel tank wiring at LH side of fuel filter.
5. Connect push lock connectors for rear fuel supply return and vapor tube at fuel filter and steel line behind fuel filter.
6. Bring left hand fuel tank support strap and right hand fuel tank support strap around fuel tank and start retaining bolt. Align fuel tank as far forward in vehicle as possible while securing retaining bolts.
7. Check hoses and wiring mounted on fuel tank top to make sure they are correctly routed and will not be pinched between fuel tank and body.
8. Tighten left hand fuel tank support strap and right hand fuel tank support strap retaining bolts to 30-40 Nm (22-30 lb ft).
9. Install fuel tank to filler pipe hoses which connect fuel tank to fuel tank filler pipes. Install hose clamps and tighten to 2.7-3.7 Nm (24-33 lb in).
10. Replace fuel drained from fuel tank.
11. Check all connections for leaks.