Fuel Tank: Removal
- Fuel tank may be drained by lowering fuel tank or if fuel pump is operating, by pumping fuel from fuel tank using a scan tool. If lowering fuel tank to drain fuel, go to step 4. If using fuel pump and scan tool to drain fuel tank, go to next step.
- Disconnect fuel supply line from fuel rail. See FUEL LINE AT FUEL RAIL . Attach end of Special Test Hose (6541, 6539, 6631 or 6923) to disconnected fuel supply line. Tool number will depend on model and/or engine application. Place remaining end of fuel hose in an approved gasoline container.
- Connect scan tool to Data Link Connector (DLC). DLC is located below instrument panel, near steering column. See Figure. Using scan tool manufacturer's instructions, activate fuel pump and pump fuel from fuel tank. Once fuel tank is empty, remove scan tool. Reinstall fuel line on fuel rail and go to next step.
- Release fuel pressure from fuel system, if not done previously. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable.
- Remove fuel tank filler cap. Remove fuel tank filler neck shroud and bezel. To prevent contaminants from entering fuel tank, reinstall fuel tank filler cap on fuel filler hose. Raise and support vehicle. Remove right/rear tire/wheel. Remove wheelhouse liner at right/rear wheel.
- Remove vertical support brackets to gain access to two ORVR vapor lines. See Fig 1. Two vapor lines connect the fuel tank to the EVAP canister and Leak Detection Pump (LDP). This connection is made near the right/rear corner of the fuel tank. Carefully disconnect these two vapor lines near top of flow management valve. See Fig 2. Be careful not to bend or kink the vapor lines. If lines leak, a DTC will be set.
- Cut plastic tie strap securing rear axle vent hose to fuel filler hoses. Disconnect electrical connector at left/front of fuel tank. See Fig 3. Disconnect two vapor lines at left/front of fuel tank. See also Fig 4. Disconnect filler neck and vent hose from tank.
- Disconnect EVAP hose from EVAP canister vent line. Disconnect fuel supply line from fuel supply tube near front of fuel tank. See FUEL LINE QUICK-CONNECT FITTINGS .NOTE: Fuel tank and skid plate are removed as an assembly. DO NOT remove fuel tank strap nuts (covered with protective caps).
- Support fuel tank with hydraulic jack. Secure fuel tank and skid plate assembly to jack. Remove three skid plate-to-body nuts at front of fuel tank. See Fig 5. Remove one of the nuts through access hole on skid plate. Remove four skid plate-to-body nuts at rear of fuel tank. See Fig 6. Do NOT loosen tank strap nuts. Lower fuel tank assembly. If fuel pump module removal is necessary. See FUEL PUMP MODULE .
- Mark and note fuel filler hose position in relation to fuel tank. Disconnect fuel filler hoses at tank. If fuel tank was not previously drained, position a siphon hose through vent fitting (smaller of two hose openings) on side of fuel tank. Drain tank into an approved gasoline container until empty.
- To separate fuel tank from skid plate, remove two protective caps from tank strap nuts. Remove tank strap nuts. Remove both straps and remove skid plate.