Fuel Tank: Service and Repair

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL

1. Perform fuel pressure release procedure.
2. Drain fuel from the fuel tank.
3. Disconnect battery ground cable.

NOTE: When the battery has been disconnected or reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

4. Raise vehicle on hoist. Use proper vehicle lifting procedures.
5. Disconnect fuel hoses and tubes.
6. On vehicles equipped with a fuel tank filler pipe retainer which fastens the fuel tank filler pipe to the fuel tank, remove the screw retaining the fuel tank filler pipe retainer to the fuel tank flange.
7. Disconnect electrical connector to the fuel pump module.
8. Place a safety support under the fuel tank. Remove the nuts from one end of the fuel tank mounting straps. The fuel tank mounting straps are hinged and will swing out of the way.
9. Remove fuel tank from the vehicle.

Fuel Tank Components (Part 1 Of 2):

Fuel Tank Components (Part 2 Of 2):

INSTALLATION

1. Before proceeding, check the following:
a. Leak check the fuel pump module.
b. Verify evaporative emission valve is properly installed on the fuel tank top.
c. Make sure clips are installed properly on tank flange and vapor tubes are secured into clips.
d. Make all required connections which will be inaccessible after the fuel tank is installed.
2. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel tank filler pipe with water base tire mounting lubricant. Install the fuel tank onto the fuel tank filler pipe then bring the fuel tank into final position.
3. Bring fuel tank mounting straps around the fuel tank and start the retaining nut or bolt. Align fuel tank with the fuel tank mounting straps and check clearance to frame and underbody.
4. Check the hoses and wiring mounted on the fuel tank top to make sure they are correctly routed and will not be pinched between the fuel tank and body.
5. Tighten the fuel tank mounting strap retaining nuts to 29-41 Nm (22-30 lb ft).
6. Fasten fuel tank filler pipe retainer, if removed. Tighten screws to 6.8-9.2 Nm (61-81 lb in).
7. Reconnect the fuel hoses and tubes which were disconnected. Make sure that the fuel supply, fuel return, and vapor vent connections are made correctly. Trace the various lines to the engine and refer to the illustrations to ensure the proper tubes are connected.
8. Connect fuel pump module electrical connector.
9. Lower vehicle.
10. Replace fuel drained from the fuel tank.
11. Connect battery ground cable.
12. Check all connections for leaks.