Partially Lower Fuel Tank

CAUTION:
DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAME IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE.

CAUTION:
ANY TIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.

NOTICE:
Fuel tank needs to be drained prior to fuel tank being lowered. If fuel tank is not drained, fuel line damage may result.

1. Disconnect negative battery cable.

2. Raise vehicle to a comfortable working position.

NOTICE:
On vehicles equipped with L81 (V-6) engine only, support catalytic converter. If catalytic converter is allowed to hang unsupported, exhaust system damage may occur.





3. Remove exhaust system intermediate pipe (with muffler).





4. Remove rear heat shield retaining bolts.

5. Remove plastic fuel tank grounding strap attachment nut from stud located near fuel filter.





6. Remove fuel tank bracket (fuel line stone chip guard) protecting fuel line connections between fuel tank and chassis fuel bundle.





7. Remove rubber exhaust pipe isolators.

IMPORTANT:
The exhaust heat shield must be completely removed or rattles may result.

8. Remove exhaust heat shield.





9. Remove two rearmost chassis fuel bundle retainers (closest to fuel tank) from underbody. Turn retainer screw counter-clockwise until screw is 110 longer backing out and pull retainer down to remove. Leave fuel lines in retainers.





CAUTION:
THE FUEL TANK HEAT SHIELD HAS SHARP METAL EDGES. CARE MUST BE USED WHEN WORKING AROUND FUEL TANK HEAT SHIELD TO AVOID PERSONAL INJURY.

10. Remove parking brake cables from underbody hooks at front of fuel tank to allow access to fuel tank strap front bolts.





NOTICE:
Do not lower front of fuel tank more than 2 inches below rear exhaust hangers or damage to fuel lines may result.

11. Pull fuel hues out of fuel line retainer on front of fuel tank





12. Remove two front bolts from fuel tank straps and carefully lower front of tank far enough to access components on top. Support front of tank with two under hoist jack stands or a transmission jack





NOTICE:
Care must be taken when removing the over pressure relief valve hose. The hose must not be cut. It must be pulled straight off valve. Any side to side or up and down movement of the hose during removal can crack the valve and require fuel tank replacement.

13. With the aid of an assistant to hold the tank steady, remove over pressure relief valve hose from over pressure relief valve by pulling straight off. Discard hose.





NOTICE:
Hose clamp tangs must point up, toward underbody of vehicle.

NOTICE:
Cap must be fully installed onto valve nipple. Clamp must be installed past the barb on valve nipple (refer to cross section view in illustration).

14. Install pressure relief valve cap (P/N 22661239) onto valve nipple and install hose clamp (P/N 90469889) onto the cap.





15. On L61 (4 cyl.) equipped vehicles, ensure the fuel tank heat shield insulator (P/N 24414677) is properly positioned in channel between fuel tank and metal fuel tank heat shield. The edge of insulator can be seen along front edge of metal fuel tank heat shield.