Fuel Tank Replacement

REMOVAL
1. Perform fuel system pressure release.
2. Drain fuel tank. Refer to Draining Fuel Tank.
3. Raise vehicle on hoist.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

Fuel Pump Module Electrical Connector:

4. Disconnect fuel pump module electrical connector.
5. Disconnect the fuel tube from Fuel Filter/Regulator. Refer to Quick Connect Fittings.
6. Support tank with transmission jack. Loosen tank mounting straps and lower tank slightly.
7. Disconnect fuel filler tube and filler vent tube from filler hose at fuel tank.
8. Disconnect fuel filler vapor relief tube from tee connecting it to the tank vapor relief tube and EVAP canister tube.
9. Disconnect vapor line from EVAP canister tube.
10. Remove tank mounting straps and lower tank.

INSTALLATION
1. Position fuel tank on transmission jack.
2. Raise tank into position. Connect fuel filler tube tank inlet nipple.
3. Tighten fuel tank strap nuts to 22.5 N.m (200 in. lbs.) torque. Remove transmission jack. Ensure straps are not twisted or bent.
4. Attach fuel tubes to pump module and chassis fuel tube. Refer to Quick Connect Fittings in the Fuel Delivery.
5. Connect fuel vapor tube to tee, then to EVAP canister tube
6. Attach electrical connector to fuel pump module.
7. Lower vehicle.
8. 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.

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