Fuel Tank Removal and Installation

REMOVAL
1. Release fuel system pressure.
2. Drain fuel tank.




3. Models with standard cabs: Disconnect vent line (3) from tank.




4. Models with extended cabs: Disconnect vent line (3) from tank.
5. If equipped, remove fuel tank skid plate.
6. Disconnect NVLD, ORVR and EVAP lines at front of tank.




7. Disconnect electrical connector at NVLD pump.
8. Support tank with a hydraulic jack.
9. Remove two fuel tank strap nuts (3) and remove both tank support straps (2).
10. Carefully lower tank a few inches and disconnect fuel pump module electrical connector at top of tank. To disconnect electrical connector: Push upward on red colored tab to unlock. Push on black colored tab while removing connector.
11. Disconnect fuel line at fuel pump module fitting by pressing on tabs at side of quick-connect fitting.
12. Continue to lower tank for removal.
13. If fuel tank is to be replaced, remove fuel pump module from tank.

INSTALLATION




1. If fuel tank is to be replaced, install fuel pump module into tank.
2. Position fuel tank to hydraulic jack.
3. Raise tank until positioned near body.
4. Connect fuel pump module electrical connector at top of tank.
5. Connect NVLD pump electrical connector to NVLD pump.
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 (2). Install two fuel tank strap nuts (3) and tighten. Refer to Torque Specifications.
9. Connect EVAP, ORVR and NVLD lines at front of tank.







10. Connect vent line (3).
11. Connect rubber fill hose (6) to fuel tank fitting and tighten hose clamps (7).
12. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD pump, NVLD filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set.
13. If equipped, install fuel tank skid plate.
14. Install plastic liner in front of left-rear tire/wheel.
15. Install left-rear tire/wheel.
16. Lower vehicle.
17. Fill fuel tank with fuel.
18. Start engine and check for fuel leaks near top of module.