Fuel Tank Replacement

CAUTION: The fuel system remains pressurized after engine has been shut off. Release system pressure prior to opening system.

WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye protection, keep open flame away from fuel system components, and prohibit smoking in service areas.

NOTE: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank replacement.

Fuel Tank Exploded View:

Fuel Filler Neck:

REMOVAL
1. Disconnect the battery negative cable.
2. Remove fuel filler cap to relieve pressure.
3. Drain fuel tank.
4. Raise vehicle and remove rear tires.
5. Pull exhaust pipe hangers off mounting studs in front of fuel tank and at rear of vehicle.

Fuel Filler And Vent Hoses:

6. Using a grease pencil, place alignment marks on fuel filler hose and filler tube. Also mark vent tube and vent hose.
7. Remove right rear wheel and splash shield in wheel well.
8. Remove vent hose from vent tube. Remove filler hose from filler tube.
9. Disconnect fuel supply tube from inlet side of fuel filter. Disconnect fuel return and vent tubes near fuel filter.

Sway Bar Ends:

10. Disconnect both ends of sway bar from stabilizer links.
11. Using a grease pencil, outline position of crossmember at frame rails.

Crossmember Bolts:

12. Remove crossmember mounting bolts, and pull crossmember down until it stops.
13. Place jack under fuel tank.
14. Remove sway bar mounting bolts, heat shield, and fuel tank strap.

WARNING: Sway bar mounting bracket bolts must be replaced after loosening or removing them. Use only original equipment bolts as replacements.

Sway Bar:

15. To prevent sway bar from falling install sway bar bracket bolts finger tight.
16. Center jack, lower jack enough to gain access to fuel pump module electrical connector.
17. Disconnect fuel pump module electrical connector.
18. Slightly lower front of fuel tank. Slide tank away from crossmember while pushing filler and vent tube over crossmember.
19. Lower fuel tank.

INSTALLATION
1. Center the tank on the jack with shield and strap in place.
2. Raise and position tank over crossmember.
3. Raise tank enough to connect fuel pump module electrical connector.
4. Push vent and filler tube over crossmember .
5. Rotate sway bar into position. Remove sway bar mounting brackets.
6. Raise tank into place. Position sway bar brackets and fuel tank strap in place. Install and tighten bolts to 44 ft.lbs. (60 Nm).
7. Raise crossmember into position. Align outline with frame rails. Install and tighten bolts to 70 ft.lbs. (195 Nm).
8. Connect filler and vent tubes to filler neck. Align marks on hose and tube, tighten clamps
9. Connect sway bar ends to stabilizer links. Install and tighten mounting bolts to 74 ft.lbs. (100 Nm).
10. Install exhaust system hangers.
11. Connect fuel supply, return and vent tubes.
12. Lower vehicle.
13. Fill fuel tank and install filler cap.
14. Connect negative battery cable.
15. Using the DRB II select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/Procedures

CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test