Fuel Tank: Service and Repair

REMOVAL
1. Perform Fuel System Pressure Release procedure as described in this group.
2. Disconnect negative battery cable at battery.
3. Remove fuel tank filler tube cap.
4. Raise vehicle on hoist.
5. If equipped, remove fuel tank skid plate.

Fig. 26 Fuel Hoses At Rear Of Fuel Tank:

6. Two rubber hoses (fuel filler and fuel vent hoses) connect the fuel tank fittings (at rear of tank) to the metal fuel fill tube assembly at body (Fig. 26). Disconnect hose clamps (Fig. 26) at fuel fill tube assembly end of hoses and disconnect rubber hoses.
7. Position a drain hose into the fuel vent hose (Fig. 26) and into tank.
8. Drain fuel into an approved portable holding tank or a properly labeled gasoline safety container.
9. Place and secure a transmission jack under center of fuel tank and apply slight pressure.

Fig. 27 Fuel Tank Mounting:

10. Remove two tank mounting nuts from mounting straps (Fig. 27). 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 rear of tank is higher than front of tank when lowering.
11. Clean quick-connect fittings (at top of fuel tank) of any dirt/contaminants before removal.
12. Disconnect fuel supply line from fuel filter/fuel pressure regulator fitting at top of tank. Refer to Quick-Connect Fittings for procedures.
13. Disconnect rear fuel vapor line (EVAP line) from fuel tank check valve at top/rear of tank.
14. Disconnect front fuel vapor line (EVAP line) from fuel tank check valve at fuel pump module.
15. Disconnect electrical connector from pump module at top of tank.
16. Lower tank from vehicle.
17. Remove tank from hydraulic jack.
18. 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. Be sure fuel filter/fuel pressure regulator inlet fitting is pointed towards front of vehicle.
2. Place and secure fuel tank on top of transmission jack.
3. Raise tank up enough to connect fuel line, electrical connector and both EVAP lines 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 Nm (20 - 40 ft. lbs.) torque. Do not over tighten mounting strap nuts.
5. Remove transmission jack.
6. Connect fill/vent hoses to fill/vent tube assembly
7. Tighten hose clamps at fill/vent hoses.
8. If equipped, install fuel tank skid plate.
9. Connect negative cable to battery.
10. Refill fuel tank and install fill cap.
11. Inspect all hoses and lines for leaks.