Fuel Tank: Service and Repair

WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN 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.

WARNING: FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE TO PREVENT POSSIBLE INJURY. REFER TO FUEL SYSTEM PRESSURE RELIEF.

Removal










1. Perform Fuel System Pressure Relief procedure.
2. Drain fuel from fuel tank (9002) as outlined.
3. Raise vehicle on hoist.
4. Loosen fuel tank filler pipe (9034) and vent hose clamps at metal lines and remove hoses.
5. Using Fuel Line Disconnect Tool Set T9OT-9550-S, disconnect push-connect fittings for rear fuel supply return and vapor tubes (9S278) at fuel filter and steel line behind fuel filter.
6. Disconnect electrical connector for fuel tank wiring at LH side of fuel filter.
7. Disconnect white plastic push-connect fitting at right rear upper corner of fuel tank that connects the line from the evaporative emission tube shut off valve (9G332) to the evaporative emission tube (9k3 13) that goes to the evaporative emissions canister (EVAP canister)(9D653).
8. Place a safety support under fuel tank and remove bolts from rear end of fuel tank support straps (9092). The fuel tank support straps are hinged at the front end and will swing out of the way.
9. On flexible fuel vehicles only, remove plastic shield and fuel tank from vehicle.

Installation

NOTE: If fuel pump module assembly has been removed, the 0-ring seal must be replaced.

1. Before proceeding, check fuel pump module unit for leaks. If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A.
2. Place fuel tank with plastic shield in its proper position in vehicle.
3. Raise vehicle on hoist.
4. Loosen fuel tank filler pipe (9034) and vent hose clamps at metal lines and remove hoses.
5. Using Fuel Line Disconnect Tool Set T9OT-9550-S, disconnect push-connect fittings for rear fuel supply return and vapor tubes (9S278) at fuel filter and steel line behind fuel filter.
6. Disconnect electrical connector for fuel tank wiring at LH side of fuel filter.
7. Disconnect white plastic push-connect fitting at right rear upper corner of fuel tank that connects the line from the evaporative emission tube shut off valve (9G332) to the evaporative emission tube (9k3 13) that goes to the evaporative emissions canister (EVAP canister)(9D653).
8. Place a safety support under fuel tank and remove bolts from rear end of fuel tank support straps (9092). The fuel tank support straps are hinged at the front end and will swing out of the way.
9. On flexible fuel vehicles only, remove plastic shield and fuel tank from vehicle.
10. Replace fuel drained from fuel tank.
11. Check all connections for leaks.