Fuel Tank: Service and Repair

REMOVAL
1. Remove fuel filler cap and perform Fuel System Pressure Release procedure.
2. Disconnect negative cable from battery
3. Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container.
4. Raise vehicle on hoist and support.
5. Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps.
6. Lower tank slightly.
7. Disconnect the fuel filler vent tube.
8. Disconnect fuel line and vapor line.
9. Disconnect the vacuum line from the NVLD.
10. Disconnect fuel filler tube by loosing the clamp and removing hose.
11. Slide fuel pump module electrical connector lock to unlock.The fuel pump module electrical connector has a retainer that locks it in place.
12. Push down on connector retainer and pull connector off module
13. Lower tank from vehicle.


INSTALLATION
1. Position fuel tank on transmission jack.
2. Raise tank into position and carefully work filler tube onto the fuel tank. A light coating of clean engine oil on the tube end may be used to aid assembly. Connect fuel filler tube hose and tighten clamp.
3. Connect fuel pump/module electrical connector. Place retainer in locked position.
4. Connect the EVAP vapor, and vacuum lines.
5. Lubricate the fuel supply line with clean 30 weight engine oil, install the quick connect fuel fitting. Refer to Tube/Fitting Assembly in the Fuel Delivery.
6. Attach filler vent line to filler tube. Pull on connector to make sure of connection.
7. Place NVLD air filter under right rear tank strap before tightening.
8. Tighten strap bolts to 54 Nm (40 ft. lbs.) torque. Remove transmission jack.
9. Tighten filler hose clamp to 3.6 Nm (31.8 in. lbs.).


CAUTION: Ensure straps are not twisted or bent before or after tightening strap nuts.

10. Fill fuel tank, replace cap, and connect battery negative cable.
11. Use the DRB III scan tool to pressurize the fuel system Check for leaks.