Fuel Tank

Fuel Tank

Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Shut off the electrical power to the air suspension system prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this instruction may result in serious personal injury.

1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury. Procedures

Release the fuel system pressure.

2. Disconnect the battery ground cable.

3. Drain the fuel tank.

4. Disconnect the Fuel Pump (FP) module electrical connector and release the retainer clip.

5. Disconnect the fuel tube-to-FP module spring lock coupling.

6. Disconnect the fuel vapor tube assembly-to-fuel vapor tube quick connect coupling.

7. Disconnect the fuel vapor tube-to-fuel vapor tube assembly quick connect coupling.

8. Completely lower and remove the fuel tank.

9. NOTE: The fuel tank strap studs are manufactured as a break-off style. After installing the new fuel tank strap studs and fuel tank installation is completed, break-off the excess length at the recess in the studs.

Remove and discard the fuel tank strap studs.





10. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury. Procedures

To install, reverse the removal procedure. If equipped with a fire suppression system, repower the system.
- Carry out the Evaporative Emission System Leak Test. Testing and Inspection