Fuel Tank: Service and Repair

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE DRAINING FUEL TANK, FUEL SYSTEM PRESSURE MUST BE RELEASED.

Two different procedures may be used to drain fuel tank (lowering tank or using DRB scan tool).

The quickest draining procedure involves lowering the fuel tank.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail connection. Refer to DRB 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 for procedures. 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 must be lowered for fuel draining. Refer to following procedures.

REMOVAL
1. Disconnect negative battery cable at battery.
2. Remove fuel tank filler tube cap.
3. Perform Fuel System Pressure Release procedure.
4. Reinstall fuel fill cap.

Fuel Fill Tube Mounting At Body:

5. The fuel fill tube assembly is mounted to a plastic bezel behind fuel fill door. Remove 3 bezel-to-body mounting screws. Do not disconnect fuel tubes from tank at this time.
6. Raise vehicle on hoist.
7. Place and secure a transmission jack under center of fuel tank and apply slight pressure.

Fuel Tank Mounting:

8. Remove two tank mounting nuts from mounting straps. Position tank mounting straps to side of vehicle and lower tank just enough to allow access to connections at top of tank. To prevent fuel loss, be sure fuel fill cap is securely installed.
9. Disconnect fuel supply line from fuel filter/fuel pressure regulator fitting at top of tank. Refer to Quick-Connect Fittings for procedures.
10. Disconnect fuel vapor line from rollover valve at top of tank.
11. Disconnect electrical connector at pump module at top of tank.
12. Lower tank from vehicle.
13. Remove tank from hydraulic jack.
14. To drain fuel from tank, one of the fuel tubes must be disconnected at side of fuel tank.
a. Rotate fuel tank until the tube fittings at side of fuel tank are at highest point.
b. Clean quick-connect fittings of any dirt/contaminants before removal.

Quick-Connect Fittings At Fuel Tubes:

Top View Of Fuel Tank:

c. Disconnect fuel vent tube quick-connect fitting at tank. The fuel vent tube is smallest of two tubes. First, push quick-connect fitting and tube as far as possible onto fuel tank fitting. While holding quick-connect fitting and tube as far as possible onto fuel tank fitting, push release sleeve squarely into quick-connect fitting to unlock release tabs. Hold sleeve into quick-connect fitting while removing tube from tank. Failure to push quick-connect fitting onto fuel tank fitting before pushing release sleeve into quick-connect fitting will damage metal retainer within fitting.
d. Position a drain hose into this open fitting on tank.
e. Drain fuel into an approved portable holding tank or a properly labeled gasoline safety container.
15. If fuel fill tube removal is necessary (fuel fill tube is largest of two tubes), push outer fitting sleeve of quick-connect fitting and pull tube from tank fitting for removal. Fitting is similar to an air hose connector.
16. If fuel pump module requires service, 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 and secure fuel tank on top of transmission jack.
3. Raise tank up enough to connect fuel line, electrical connector and vapor hose to top of fuel tank. Refer to Quick-Connect Fittings for fuel line procedures.
4. Continue raising tank into position and install mounting straps and nuts. Tighten nuts to 27-54 N-m (20-40 ft. lbs.) torque. Do not over tighten mounting strap nuts.
5. Install fuel tube quick-connect fittings to tank fittings. Be sure they are clean of any dirt/contaminants before installation. Quick-Connect fittings snap on to tank fittings. After installation, pull firmly on each tube to confirm good connection to tank fitting. After verifying good connection, gap from bottom of fuel fill tube sleeve to top of tank fitting should be approximately 1/4 inch. Gap from bottom of fuel vent tube sleeve to top of tank fitting should be approximately 1/2 inch.
6. Remove transmission jack.
7. Install fuel tube assembly and plastic bezel to body (3 screws).
8. Connect negative cable to battery.
9. Refill fuel tank and install fill cap.
10. Inspect all hoses and lines for leaks.