Fuel Tank: Service and Repair

REMOVAL

Fuel Tank Draining

WARNING: THE FUEL SYSTEM MAY BE UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK.




Two different procedures may be used to drain fuel tank: through the fuel fill fitting on tank, or using the DRBII (R) scan tool.

The quickest draining procedure involves removing the rubber fuel fill hose (7) from fuel tank fitting.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail connection. Refer to DRBII(R) 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, fuel must be drained through fuel fill fitting at tank. Refer to following procedures.

1. Release fuel system pressure.
2. Raise vehicle.
3. If equipped, remove fuel tank skid plate.
4. Thoroughly clean area around fuel fill fitting and rubber fuel fill hose (7) at rear of fuel tank.
5. Loosen clamp (9) and disconnect rubber fuel fill hose at fuel tank fitting. Using an approved gas holding tank, drain fuel tank through this fitting.




1. Loosen clamp and disconnect rubber fuel vent hose (8) at tank fitting.
2. Support tank with a hydraulic jack.







3. Remove two fuel tank strap bolts (3) and remove both tank support straps (4).
4. Carefully lower tank a few inches and disconnect fuel pump module electrical connector (5) at top of tank. To disconnect electrical connector: Push upward on red colored tab to unlock. Push on black colored tab while removing connector.
5. Disconnect fuel line (6) at fuel pump module fitting by pressing on tabs at side of quick-connect fitting.
6. Disconnect NVLD, ORVR and EVAP lines (10) at front of tank.
7. Continue to lower tank for removal.
8. If fuel tank is to be replaced, remove fuel pump module from tank. Refer to Fuel Pump Module Removal/Installation procedures.

INSTALLATION
1. If fuel tank is to be replaced, install fuel pump module into tank. Refer to Fuel Pump Module Removal/Installation procedures.
2. Position fuel tank to hydraulic jack.
3. Raise tank until positioned near body.
4. Connect EVAP, ORVR and NVLD lines at front of tank.
5. Connect fuel pump module electrical connector at top of tank.
6. Connect fuel line quick-connect fitting to pump module.
7. Continue raising tank until positioned snug to body.
8. Install and position both tank support straps. Install two fuel tank strap bolts and tighten. to 41 N.m (30 ft. lbs)
9. Connect rubber fill and vent hoses to fuel tank fittings and tighten hose clamps.
10. If equipped, install fuel tank skid plate.
11. Lower vehicle.
12. Fill fuel tank with fuel.
13. Start engine and check for fuel leaks near top of module.