Fuel Tank Draining and Removal/Installation

FUEL TANK DRAINING AND REMOVAL/INSTALLATION PROCEDURE


REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

1. Disconnect negative cable from battery.
2. Remove fuel filler cap and perform Fuel System Pressure Release procedure. Service and Repair
3. Insert fuel syphon hose into fuel filler neck and push it into the tank.
4. Drain fuel tank dry into holding tank or a properly labeled gasoline safety container.
5. Raise vehicle on hoist.





6. Disconnect both the fuel fill and fuel vent rubber hoses at the fuel tank.
7. Disconnect fuel supply lines from fuel pump module, located on top of fuel tank. The fuel pump module electrical connector has a retainer that locks it in place.





8. Slide fuel pump module electrical connector lock to unlock.





9. Push down on connector retainer and pull connector off module.
10. Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps.
11. Lower tank slightly. Carefully remove filler hose from tank.
12. Lower the fuel tank. Disconnect pressure relief/rollover valve hose. Remove clamp and remove fuel filler tube vent hose. Remove fuel tank from vehicle.

INSTALLATION
1. Position fuel tank on transmission jack. Connect pressure relief/rollover valve hose. Connect fuel filler tube vent hose and replace clamp.
2. Raise tank into position and carefully work filler tube into tank. A light coating of clean engine oil on the tube end may be used to aid assembly.
3. Tighten strap bolts to 54 Nm 40 ft. lbs. torque. Remove transmission jack.

CAUTION: Ensure straps are not twisted or bent before or after tightening strap nuts.

4. Connect fuel pump/module electrical connector. Place retainer in locked position.
5. Lubricate the fuel Tine with clean 30 weight engine oil, install the quick connect fuel fitting.
6. Fill fuel tank, replace cap, and connect battery negative cable.

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 Off position.

7. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for Teaks.