Procedures

DRAINING FUEL TANK

Special Tools:






Conventional Procedure

WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area and free of flames/sparks. Failure to comply may result in serious or fatal injury.

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.

CAUTION: If the electric fuel pump is not operating, and the fuel level is above 5/8 of a tank, the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.

CAUTION: If the fuel level sending unit is not operating, and the fuel level cannot be determined the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.

NOTE: Due to a one-way check valve installed into the fuel fill fitting at the tank, the tank cannot be drained at the fuel filler tube.





1. Perform the fuel system pressure release procedure Service and Repair.
2. Disconnect the fuel supply line (2) from the fuel rail Service and Repair






NOTE: Tool number 8978-2 is used on 5/16" fuel lines while tool number 8531-1 is used on 3/8" fuel lines.

3. Install the appropriate fuel line adapter fitting from the (8978A) to the fuel supply line. Route the opposite end of this hose to an OSHA approved fuel storage tank such as the JohnDow Gas Caddy 320-FC-P30-A or equivalent.

NOTE: Due to a built in time out feature of the diagnostic scan tool, the fuel pump may need to be reactivated several times before the fuel tank evacuation is complete.

4. Using a diagnostic scan tool, activate the fuel pump until the fuel tank has been evacuated.

Alternative Procedure

WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area and free of flames/sparks. Failure to comply may result in serious or fatal injury.

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.

CAUTION: The fuel level of the vehicle must be below 5/8 of a tank before using the "Alternative Procedure". If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.

CAUTION: If the electric fuel pump is not operating, and the fuel level is above 5/8 of a tank, the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.

CAUTION: If the fuel level sending unit is not operating, and the fuel level cannot be determined the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.





1. Verify the fuel level is below 5/8 of a tank.
2. Perform the fuel system pressure release procedure Service and Repair.
3. Disconnect the negative battery cable (1).





4. Push the rear lower seat cushion up and back and remove the seat cushion.





5. Fold back the foam pad covering the fuel pump module plastic access covers.





6. Remove the left side fuel pump module plastic access cover.





7. Disconnect the electrical connector from the fuel pump module.

CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.






NOTE: Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.

8. Mark the fuel pump module orientation.
9. Position the SAE Fuel Pump Lock Ring Wrench (1) into the notches on the outside edge of the lock ring.
10. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (1).
11. Rotate the breaker bar counterclockwise and remove the lock ring.

CAUTION: Do not spill fuel into the interior of the vehicle.

CAUTION: The lower reservoir of the fuel pump module must be drained before removal or fuel can spill into the interior of the vehicle.





12. Lift the fuel pump module up enough to push a 3/8 inch hose into the fuel tank.
13. Attach the opposite end of this hose to an OSHA approved fuel storage tank such as the JohnDow Gas Caddy 320-FC-P30-A or equivalent.
14. Using the gas caddy, evacuate the left side of the fuel tank.





15. Remove the right side auxiliary fuel pump module plastic access cover (1).





16. Disconnect the fuel supply line (2) at the auxiliary fuel pump module (1).

CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.






NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.

17. Mark the auxiliary fuel pump module orientation.
18. Position the SAE Fuel Pump Lock Ring Wrench (1) into the notches on the outside edge of the lock ring (2).
19. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (1).
20. Rotate the breaker bar counterclockwise and remove the lock ring.





21. Lift the auxiliary fuel pump module up enough to push a 3/8 inch hose (1) into the fuel tank.
22. Attach the opposite end of this hose to an OSHA approved fuel storage tank such as the JohnDow Gas Caddy 320-FC-P30-A or equivalent.
23. Using the gas caddy, evacuate the right side of the fuel tank.