Fuel Tank: Service and Repair

CAUTION: The fuel system remains pressurized after engine has been shut off. Release system pressure prior to opening system.

WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye protection, keep open flame away from fuel system components, and prohibit smoking in service areas.

NOTE: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank replacement.

Fuel Tank Exploded View:

Fuel Filler Neck:

REMOVAL

1. Disconnect the battery negative cable.
2. Remove fuel filler cap to relieve pressure.
3. Drain fuel tank.
4. Raise vehicle on a hoist.
5. Remove right rear wheel and splash shield in wheel well.
6. Remove ground wire by filler neck.
7. Disconnect vent hose from filler neck and pull hose out of retaining clip on frame.
8. Remove two nuts holding fuel tank support strap and push strap through left frame rail.
9. Support tank with a suitable jack.
10. Clean connectors with a clean rag and compressed air before disconnecting to prevent system contamination. Disconnect the quick-connect fittings by squeezing the retainer tabs and pulling the fitting back.

NOTE: Wrap the fuel supply tube and fuel filter lines with a shop towel before disconnecting the quick-connect fittings to absorb any fuel spills.

NOTE: The retainer will remain on the nipple.

11. Pull fuel tank to filter supply tube through hole in cross member toward fuel tank.
12. Disconnect pump/sending unit electrical connector. The connector is attached to the frame.
13. Disconnect the vapor hose and fuel return tube.
14. Remove tank mounting bolts. The fuel tank is now supported only by the jack.
15. Lower the tank two to three inches. Push vent hose through hole in frame toward tank.

NOTE: To remove the tank it is necessary to tip the rear of the tank down for the mounting flanges to clear the rear axle. Support the tank accordingly so it does not fall while it is being lowered.

16. Lower the tank.

Fuel Tank Installed:

INSTALLATION

1. Center the tank on the jack under rear of vehicle.
2. Raise the transmission on the jack until the top of tank is 8 to 10 inches from vehicle.
3. Tilt the tank so the mounting flanges clear the rear axle and raise tank slowly until it is about two inches away from being in place.
4. Push vent hose through hole in frame, and raise tank into position. Install mounting bolts and torque to 12 lb-ft (16 N-m).
5. Remove jack, install support strap and tighten nut until the distance between the bottom of the strap bolt and the strap is 54-60 mm (2.125-2.362 in.)
6. Install lock nut and tighten
7. Push fuel supply tube through hole in cross member, reconnect fuel lines.
8. Connect electrical connector, connect vapor hose and fuel return tube, attach vent hose to filler neck and replace vent hose in clip on body.
9. Reattach ground wire by filler neck.
10. Install splash shield in wheel well, install rear wheel, lower vehicle, fill tank, install fuel filler cap, and connect negative battery cable.
11. Using the DRB II select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/Procedures

CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test