Fuel Tank Removal and Installation

Fuel Tank Removal and Installation

Special Tool:

Warning: Do not smoke, carry lighted tobacco or open flame of any type when working on or near fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

Warning: The evaporative emissions system contains fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground to minimize the possibility of an electrical spark occuring, possibly causing fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.

Warning: The fuel in the system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or fire hazard.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Release the fuel system pressure.
4. Remove the rear driveshaft.






5. Disconnect the lower fill hose from the fuel intermediate steel by loosening worm gear clamp and pulling it off.






6. Insert a drain hose through the lower fill hose, past the fill tube check valve, and pump fuel out of the fuel tank.






7. Remove the fuel tank skid plate (if equipped).
1. Remove the three bolts at the outboard frame rail.
2. Remove the two nuts on the inboard side.
3. Remove the fuel tank skid plate.






8. If equipped, remove the transfer case skid plate by removing four bolts from the outer frame rail (two per side).






9. Disconnect the transmission-mounter fuel vapor line from the plastic fitting on the forward canister. This a squeeze release connector.






10. Remove the fuel filter hear shield from the nose of the fuel tank.
1. Remove the two nuts,
2. Remove the heat shield.






11. Disconnect the transmission-mounter fuel supply line from the fuel filter. There is a redundant latch that will unlock first. Then a quick-connect fitting that will require a quick disconnect tool to remove.






12. Push the fuel line out of the retaining clip at the top rear of the fuel tank.






13. Disconnect the vapor line on the filler pipe from the tank (quick connector is on the frame rail side of the tank on the top in the rear and can be accessed through the passenger rear tire opening or from the ground with the vehicle on a hoist). Push the button on the side to release.






14. Disconnect the vapor line from the canister vent, which is located on the inside frame rail just rearward of the fuel tank.






15. Use a suitable jack to support the fuel tank.






16. Remove the fuel tank strap nut.






17. Remove the fuel tank strap bolt and lower tank.






18. Lower the tank slightly and disconnect the electrical connector from the fuel pump sender to the frame loom.
19. Remove the fuel tank.
20. To install, reverse the removal procedure.