Fuel Tank Removal and Installation

REMOVAL

Battery Cable:

1. Disconnect the negative battery cable.
2. Perform fuel system pressure release, refer to the fuel system pressure release procedure.
3. Raise and support vehicle on hoist.
4. Disconnect vapor line from EVAP canister tube.

EVAP Canister:

5. Remove EVAP canister.

Fuel Tank:

6. Drain fuel tank. Remove the drain port cap and remove fuel. Drain fuel tank into holding tank or a properly labeled Gasoline safety container. Reinstall drain port cap when done draining fuel.

Pump Module Electrical Connector:

7. Disconnect fuel pump module electrical connector and ground wire.
8. Disconnect the fuel tube from Fuel Filter/Regulator. Refer to Quick Connect Fittings in the Fuel Delivery.
9. Disconnect fuel filler tube and filler vent tube from filler hose at fuel tank.
10. Support tank with transmission jack. Loosen tank mounting straps and lower tank slightly.
11. Remove tank mounting straps and lower tank.

INSTALLATION
1. Position fuel tank on transmission jack.
2. Raise tank into position.
3. Tighten fuel tank strap nuts to 22.5 Nm (200 in. lbs.) torque. Remove transmission jack. Ensure straps are not twisted or bent.
4. Connect fuel filler tube tank inlet nipple. Tighten clamp.
5. Connect EVAP vent hose.
6. Attach fuel tubes to pump module and chassis fuel tube. Refer to Quick Connect Fittings in the Fuel Delivery.
7. Attach electrical connector and ground wire to fuel pump module.
8. Install vapor lines to EVAP canister.
9. Install EVAP canister.
10. Lower vehicle.
11. Fill fuel tank, install filler cap, and connect battery cable.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

12. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.