Fuel Tank Draining and Removal/Installation
FUEL TANK DRAINING AND REMOVAL/INSTALLATION PROCEDURE
Fuel Tank Mounting:
WARNING: The fuel system is under constant fuel pressure even with the engine off. This pressure must be released before servicing fuel tank.
The electric fuel pump may be activated allowing fuel tank to be drained. This is done at fuel rail connection using DRB scan tool. Refer to scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure. Attach end of special test hose tool number 6541, 6539 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and drain tank until empty. If electric fuel pump is not operating, tank will have to be lowered for fuel draining. Refer to the following procedure.
REMOVAL
1. Remove fuel tank filler tube cap to release fuel tank pressure.
2. Perform Fuel System Pressure Release procedure.
3. Disconnect negative battery cable at battery.
4. Raise vehicle on hoist.
5. open fuel fill door and remove screws mounting fuel filler tube assembly to body. Do not disconnect rubber fuel fill or vent hoses from tank at this time.
6. Place a transmission jack under the center of the fuel tank. Apply a slight amount of pressure to fuel tank with transmission jack.
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 only enough to allow access to top of tank. The 2 tank fittings (where rubber fuel fill and vent hose connections are made) must be positioned above tank level. Rotate tank slightly to allow these fittings to be above tank level.
WARNING: Wrap shop towels around hoses to catch any gasoline spillage.
9. While working over the left rear tire/wheel, disconnect the rubber fuel vent hose and clamp at fuel tank (vent hose is the smallest of 2 hoses). Position fuel siphoning/drain hose into this opening at tank. Drain fuel into an approved portable holding tank or a properly labeled gasoline safety container
Fuel Filler Tube Location:
10. Disconnect the fuel fill rubber hose at fuel tank.
11. While working over the left rear tire/wheel. disconnect the electrical connector from the fuel pump module.
12. Disconnect the EVAP hose at the pressure relief/rollover valve.
13. Disconnect the fuel supply line at the fuel filter/fuel pressure regulator. Refer to Quick-Connect Fittings for procedures.
14. If fuel pump module removal is necessary. refer to Fuel pump module Removal/Installation.
INSTALLATION
1. If fuel pump module is being installed. Refer to Fuel Pump module Removal/Installation.
2. Place fuel tank on top of transmission jack.
3. Install the rubber fill and vent lines. to tank.Tighten hose clamps to 2.3 Nm (20 in. lbs.) torque.
4. Raise tank into position while guiding fill and vent hoses to body. Raise tank only enough to allow access to top of tank.
5. Connect the electrical connector to the fuel pump module.
6. Connect the EVAP hose at the pressure relief/rollover valve.
7. Connect the fuel supply line at the fuel filter/ fuel pre sure regulator. Refer to Quick-Connect Fittings for procedures.
8. Connect the two mounting straps and mounting strap nuts.
9. Tighten strap nuts to 41 Nm (30 ft. lbs.) torque. Do not over tighten retaining strap nuts.
10. Remove transmission jack.
11. Connect fuel filler tube assembly to body.
12. Refill fuel tank and inspect all hoses and lines for leaks.
13. Connect negative battery cable to battery.