Fuel Tank Removal/Installation Procedure
FUEL TANK REMOVAL/INSTALLATION PROCEDURE
REMOVAL - ALL WHEEL DRIVE
1. Perform the Fuel System Pressure Release Procedure.
2. Disconnect battery ground cable.
3. Remove fuel filler cap.
4. Drain fuel tank. Refer to Fuel Tank Draining Procedure.
5. Remove screws that hold filler tube to opening in quarter panel.
6. Raise vehicle on hoist.
Brake Cable Support Bracket:
7. Remove fasteners holding the park brake cable support bracket assembly in place.
Fuel Tank Assembly:
8. Use a transmission jack to support the fuel tank. Remove the bolts from the fuel tank straps.
9. Loosen fuel filler tube vent hose clamp and remove hose from tube.
10. Lower tank slightly.
11. Clean the quick connectors to remove any dirt. Use air pressure or an appropriate cleaning agent. Disconnect fuel supply and return hoses from the chassis fuel tubes by pushing in on the black plastic release ring and pulling on the connector.
12. Disconnect the fuel vent hose. Plug hoses to prevent contamination. The fuel pump module electrical connector has a retainer that locks it in place.
13. Slide fuel pump module electrical connector retainer to the unlock position.
Fuel Pump:
14. Remove electrical connector from the fuel pump module.
15. Pull fuel filler vent hose through the frame rail.
16. Lower the fuel tank and remove the fuel filler tube from the fuel tank.
INSTALLATION - ALL WHEEL DRIVE
1. Position fuel tank on transmission jack. Insert fuel filler tube into opening in tank.
2. Raise fuel tank while inserting fuel filler vent hose through hole in frame rail.
3. Ensure that the black release rings of the supply and return fuel hose quick connect fittings are in the OUT position. The release ring should be loose and free floating.
4. Lubricate the ends of the chassis fuel tubes supply and return only with clean 30 weight engine oil.
CAUTION: When making connections with quick connect fittings, always pull back on the fitting to ensure complete engagement. If the fitting will not fully connect, make sure the black release ring is not lammed into the metal casing of the fitting. If the fitting fails, replace it with a new one of the correct size.
5. Couple quick connect fittings of the fuel supply and return hoses to the chassis fuel tubes.
6. Connect the fuel tank vent hose to the chassis fuel tube.
7. Connect fuel pump electrical connector to the fuel pump module. Place retainer in locked position.
8. Install drain tube cap.
9. Raise fuel tank into position. Carefully twist the filler tube and fuel filler vent tube into position.
CAUTION: Be sure straps are not twisted or bent before or after tightening strap nuts.
10. Install fuel tank support straps. Tighten fasteners to 54 Nm 40 ft. lbs. torque. Remove the transmission jack.
11. Connect fuel filler vent hose and tighten hose clamp.
12. Install park brake cable support bracket. Tighten the fasteners to 23 Nm 200 in. lbs. torque.
13. Lower vehicle.
14. Attach filler tube to filler neck opening in quarter panel. Tighten quarter panel screws to 2 Nm 17 in. lbs. torque. On affected models, install gasket between the filler tube and the inner quarter panel before installing the mounting screws.
15. Fill fuel tank, replace cap, connect battery ground cable and check system operation.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Oft position.
16. Pressurize the system using the DRB scan tool. With ignition key in the Run position, use ASD Fuel System Test. This will activate the fuel pump and pressurize the system. Check system for leaks.