Fuel Tank: Service and Repair

WARNING: THE FUEL SYSTEM IS 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 (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
On this model, the fuel tank is mounted to vehicle skid plate. The skid plate is mounted to vehicle body.
1. Remove fuel filler cap.
2. Perform the Fuel System Pressure Release Procedure as described elsewhere.
3. Disconnect negative battery cable.

Fuel Filler Hoses/Fuel Fill Cap:

4. Remove 8 screws retaining plastic fuel filler bezel to body. Remove fuel filler bezel.
5. To prevent contaminants from entering tank, temporarily install fuel cap to fill hoses.
6. Cut plastic tie wrap securing rear axle vent hose to fuel filler hoses.

Fuel Tank Connections:

7. Disconnect electrical connector at front of fuel tank.
8. Disconnect EVAP hose from EVAP line at front of fuel tank.
9. Disconnect quick-connect fitting from fuel line at front of fuel tank. Refer to Quick-Connect Fittings for procedures.
10. The fuel tank and skid plate are removed as an assembly. Centrally position a transmission jack (or equivalent lifting device) under skid plate/fuel tank assembly. Secure tank assembly to jack.

Fuel Tank Mounting Nuts - Front:

11. Remove three skid plate-to-body nuts at front of tank. Remove one of the nuts through access hole on skid plate.

Fuel Tank Mounting Nuts - Rear:

12. Remove four skid plate-to-body nuts at rear of tank. Do not loosen tank strap nuts.
13. Lower the tank assembly.
14. If fuel pump module is to be removed, refer to Fuel Pump Module Removal/installation.
15. Disconnect fuel filler hoses at tank. Before disconnecting, mark and note the hose rotational position in relation to tank fittings.
16. Using an approved portable gasoline siphon! storage tank, drain fuel from tank. To drain fuel, position drain hose into vent fitting (smallest of 2) on side of tank.
17. To separate tank from skid plate, remove two protective caps at tank strap studs and remove tank strap nuts.
18. Remove both straps and remove tank from skid plate.

INSTALLATION
1. Place fuel tank into skid plate. Wrap straps around tank with strap studs inserted through holes in skid plate. Tighten strap nuts to attain 30 mm (+2 mm) between bottom of nut to end of strap stud. Do not over tighten nuts.
2. Install two protective caps to tank strap studs.
3. Connect fuel filler hoses at tank. Tighten hose clamps.
4. Raise skid plate/fuel tank assembly into position on body while guiding filler hoses.
5. Install 7 skid plate mounting nuts. Tighten to 16 Nm (141 in. lbs.) torque.
6. Remove tank jacking device.
7. Connect electrical connector at front of fuel tank.
8. Connect EVAP hose to EVAP line at front of fuel tank.
9. Connect quick-connect fitting to fuel line at front of fuel tank. Refer to Quick-Connect Fittings for procedures.
10. Use a new plastic tie wrap to secure rear axle vent hose to fuel filler hoses.
11. Position fuel filler bezel to body. Install 8 screws and tighten.
12. Fill fuel tank. Install filler cap.
13. Connect negative battery cable to battery.
14. Start vehicle and inspect for leaks,