Fuel Tank Removal and Installation

REMOVAL
1. Remove fuel filler cap and perform Fuel System Pressure Release procedure.
2. Disconnect negative cable from battery.
3. Insert fuel siphon 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 and support.
6. Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps.
7. Lower tank slightly.

Fig. 16 Fuel Filler And Vent Tube:

8. Disconnect the fuel filler vent tube. Squeeze tabs and pull apart (Fig. 16).
9. Disconnect the fuel fill hose at the fuel tank filler metal tube NOT AT THE FUEL TANK (Fig. 16).
10. Disconnect fuel line and vapor line at the front of the fuel tank.
The fuel pump module electrical connector has a retainer that locks it in place.

Fig. 17 Fuel Line Retainers And Pump Connector Lock:

11. Slide fuel pump module electrical connector lock to unlock (Fig. 17).

Fig. 18 Pump Module Connector Retainer And Lock:

12. Push down on connector retainer (Fig. 18) and pull connector off module.

Fig. 19 Vent Hose:

13. Lower tank from vehicle. Remove fuel filler vent tube from frame (Fig. 19).

INSTALLATION
1. Position fuel tank on transmission jack. Connect rollover valve hose. Connect fuel filler tube vent hose and tighten clamp.
2. Raise tank into position and carefully work filler metal tube into the rubber hose on fuel tank. A light coating of clean engine oil on the tube end may be used to aid assembly.
3. Feed filler vent line thru frame rail. Careful not to cross lines.
4. Tighten strap bolts to 54 Nm (40 ft. lbs.) torque. Tighten T strap bolt to 28.2 Nm (250 in. lbs.). Remove transmission jack.
5. Tighten filler hose clamp to 3.3 Nm (30 in. lbs.).

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

6. Connect fuel pump/module electrical connector. Place retainer in locked position.
7. Lubricate the fuel supply line with clean 30 weight engine oil, install the quick connect fuel fitting.

8. Attach filler vent line to filler tube. Pull on connector to make sure of connection.
9. Fill fuel tank, replace cap, and connect battery negative cable.
10. Use the DRBIII(R) scan tool to pressurize the fuel system. Check for leaks.