Removal of Tank

Drain Fuel Tank

CAUTION: Do Not Allow Smoking Or The Use Of Open Flames In The Area Where Work On The Fuel System Is Taking Place.

CAUTION: Never Drain Or Store Fuel In Any Open Container Due To The Possibility Of Fire Or Explosion.

CAUTION: Make Sure Vehicle Is Properly Supported And Squarely Positioned. To Help Avoid Personal Injury When A Vehicle Is On A Hoist, Provide Additional Support For The Vehicle On The Opposite End From Which Components Are Being Removed.

1. Position vehicle on hoist.

CAUTION: Fuel Supply Lines Will Remain Pressurized For Long Periods Of Time After The Engine Is Shutdown. This Pressure Must Be Relieved Before Servicing The Fuel System.

2. Relieve fuel system pressure.

a. Connect Scan tool to vehicle diagnostic connector and start vehicle.

b. Use Scan tool to command fuel pump Off. (Refer to Tech 2 User Guide for proper Scan tool navigation and setup.)

c. Engine will stall in 3-5 seconds.

3. Raise vehicle on hoist to comfortable working height, keeping Scan tool outside of vehicle and accessible from under vehicle.

CAUTION: Whenever Fuel Line Fittings Are Loosened, Wrap A Shop Cloth Around The Fitting And Have An Approved Container Available To Collect Any Fuel.

4. Disconnect fuel feed line at outlet to fuel filter.





5. Install 3/8" x 1/4" quick connect (1) adapter from flow/pressure adapter (SA9127E-7) into fuel feed line.

6. Connect suitable drain hose to other end of adapter, and connect drain hose to certified fuel handling cart.

7. Energize fuel pump using Scan tool. (Refer to Tech 2 User Guide for proper Scan tool navigation and setup.)

8. Pump out fuel until no more fuel flows from line.

9. Lower vehicle.

REMOVE 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.

1. Disconnect negative battery cable.

2. Raise vehicle to a comfortable working position.

NOTICE: On vehicles equipped with L81 ('7-6) engine, 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 fuel filler pipe lower bracket attachment screw.

CAUTION: Whenever Fuel Lines Are Removed, Place Fuel In An Approved Container. Container Opening Must Be A Minimum Of 300 MM (12 IN.) Diameter To Adequately Catch Fuel.

6. Disconnect EVAP canister vent hose.





7. Disconnect quick connect at recirc. line.

8. Loosen fuel filler pipe hose clamp closest to fuel tank.

9. Disengage fuel filler pipe hose from fuel tank.





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

11. Disconnect fuel tank electrical connection and remove connector from underbody.

12. Remove fuel tank strap bracket protecting fuel line connections between fuel tank and chassis fuel bundle.

CAUTION: Whenever Fuel Lines Are Removed, Place Fuel In An Approved Container. Container Opening Must Be A Minimum Of 300 MM (12 IN.) Diameter To Adequately Catch Fuel.





13. Disconnect fuel feed line behind fuel filter.

14. Disconnect fuel return and EVAP canister purge lines between tank and chassis fuel bundle.





15. Loosen front tank strap bolts, but do not remove.

16. With aid of an assistant, remove the two rear tank retaining strap bolts.

a. Lower rear half of tank and slide the fuel tank down and out rearward.

b. Remove fuel tank from vehicle.