Removal and Installation
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.
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.
Fuel Tank Lockring Wrench:
Fuel Line Disconnect Tool Set:
SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Rotunda Powertrain Lift 014-00765
Item Description
1 Fuel and Vapor Return Tube
2 Rear Fuel Supply Return and Vapor Tube
3 Evaporative Emission Valve
4 Evaporative Emission Tube Shut Ott Valve
5 Fuel Tank Vent Tube
6 Evaporative Emission Tube
7 Fuel Filter and Base
8 Pierce Nut (Part of Body)
9 Screw
10 Body
11 Screw
12 Clip/Tether
13 Fuel Injection Supply Manifold
14 U-Nut (2 Required)
15 Fuel Tank Pressure/Vacuum Transducer
16 Fuel Tank
17 Screw (2 Required)
18 Fuel Filter and Base
19 Evaporative Emission Tube
20 Evaporative Emission Canister Purge Valve
21 Fuel Vapor Canister Purge Outlet Tube
A Tighten to 5-7 N.m (45-61 Lb-In)
B Tighten to 9-12 Nm (80-106 Lb-In)
REMOVAL
1. Disconnect negative battery cable.
2. Connect Fuel Pressure Gauge T80L-9974-B to the fuel pressure relief valve on the fuel injection supply manifold and relieve fuel system pressure by opening the manual valve on the Fuel Pressure Gauge T80L-9974-B.
3. Raise vehicle on hoist.
4. Drain fuel from fuel tank.
5. Loosen fuel tank filler pipe, vent hose and vapor hose clamps at metal lines and remove hoses.
6. Disconnect fuel supply line at fuel filter, return line beneath fuel filter, and vapor tube fitting at right rear of tank.
7. Position Rotunda Powertrain Lift 014-00765 or equivalent under vehicle and raise to fuel tank.
8. Remove the two bolts retaining fuel tank support straps. Using a magnet, remove pins retaining support straps to vehicle and remove straps. Lower the fuel tank just enough to gain access to electrical connector for fuel tank wiring at left hand side of fuel filter and disconnect connector.
9. Remove plastic shield.
10. Lower fuel tank from vehicle.
INSTALLATION
1. Position plastic shield.
2. Position fuel tank onto powertrain lift and position lift under vehicle. Raise powertrain lift and connect electrical connector for fuel tank wiring at LH side of fuel filter.
3. Raise tank into place and install support strap pins, straps and bolts. Tighten bolts to 30-40 N.m (22-30 Lb-Ft).
4. Remove powertrain lift from under vehicle.
5. Connect fuel lines to filter, purge tube to metal line, filler hose, vent hose, and vapor hose to filler neck and tighten clamps securely.
6. Lower vehicle.
7. Connect battery negative cable.
8. Disconnect and remove fuel pressure gauge from vehicle.
9. Fill fuel tank.