Fuel Tank Removal/Installation Procedure

FUEL TANK REMOVAL/INSTALLATION PROCEDURE

Fuel Tank Fill And Vent Hoses:

REMOVAL
1. Disconnect negative battery cable at battery
2. Remove fuel tank filler tube cap.
3. Drain fuel tank. Refer to the previous Draining Fuel Tank section.
4. Disconnect both the fuel fill and fuel vent rubber hoses at the fuel tank.

Fuel Tank Location (Gas):

Fuel Tank Connections (Diesel):

5. GAS POWERED ENGINES: While working over the left rear tire/wheel:
a. Disconnect the electrical connector from the fuel pump module.
b. Disconnect the EVAP hose at the pressure relief/rollover valve.
c. Disconnect the fuel supply line at the fuel filter/fuel pressure.

DIESEL POWERED ENGINES: While working over the left rear tire/wheel:
a. Disconnect the electrical connector from the fuel tank module.
b. Disconnect the fuel supply and fuel return lines at the fuel tank module.

6. Place a transmission jack under the center of the fuel tank. Apply a slight amount of pressure to fuel tank with transmission jack.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY FUEL SPILLAGE.

Fuel Tank Mounting (Typical):

7. Remove the fuel tank mounting strap nuts at the mounting straps. If equipped, remove the fuel tank heat shield bolts.
8. Lower fuel tank for removal.

INSTALLATION
1. Place fuel tank on top of transmission jack.
2. Raise tank into position in the frame cross-members.
3. Connect the two mounting straps and mounting strap nuts.
4. Remove transmission jack. Tighten strap nuts to 9 Nm (80 in lb) torque. Do not over tighten retaining strap nuts.

5. GAS POWERED ENGINES:
a. Connect the electrical connector to the fuel pump module.
b. Connect the EVAP hose at the pressure relief/rollover valve.
c. Connect the fuel supply line at the fuel filter/fuel pressure regulator.

DIESEL POWERED ENGINES:
a. Connect the electrical connector to the fuel tank module.
b. Connect the fuel supply and fuel return lines at the fuel tank module.

6. Install the rubber fill and vent lines to tank. Tighten hose clamps to 2.3 Nm (20 in lb) torque.
7. Refill fuel tank and inspect all hoses and lines for leaks.
8. Connect negative battery cable to battery.