Fuel Tank: Removal

Fuel level in tank below 3/4:  fuel tank draining is not necessary for tank removal.

Fuel level in tank above 3/4:  the electric fuel pump may be activated allowing tank to be partially drained at fuel rail connection. Refer to DRB Scan Tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, remove gas cap and release fuel pressure. Refer to the STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE  for procedures. Attach end of Special Adapter Hose Tool number 6539 at fuel rail disconnection. Position opposite end of 6539 to an approved gasoline draining station.

Activate fuel pump with DRB and drain approximately 4-5 gallons of fuel before tank removal. The fuel tank does not need to be completely emptied before removal.

Electric fuel pump not operating, and fuel level in tank above 3/4:  the fuel tank does not need to be completely emptied before removal. Before disconnecting fuel line at fuel rail remove gas cap and release fuel pressure. Attach an approved, suction type gasoline draining station to disconnected fuel line at fuel rail, Drain approximately 4-5 gallons of fuel before tank removal.

1. Release fuel system pressure Refer toSTANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE  .
2. Disconnect negative battery cable at battery.
3. Raise and support vehicle.
4. Remove left rear wheel tire.
   CAUTION: HANDLE EVAP LDP AND ORVR VAPOR/VACUUM LINES VERY CAREFULLY. THESE LINES AND HOSES MUST BE FIRMLY CONNECTED. CHECK THE VAPOR/VACUUM LINES AT THE LDP, LDP FILTER, EVAP CANISTER, EVAP CANISTER PURGE SOLENOID AND OVER COMPONENTS (Fig 1 ) FOR DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
   Fig 1: Components At Top Of Fuel Tank

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5. Remove stone shield behind left/rear wheel (Fig 2 ). Drill out plastic rivets for removal.
   Fig 2: Stone Shield

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6. Remove 3 LDP mounting bolts (Fig 3 ).
7. Remove support bracket brace bolt (Fig 4 ).
8. Loosen, but do not remove 2 support bracket nuts at frame rail (Fig 3 ).
   Fig 3: LDP Mounting Bolts

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9. To separate and lower front section of two piece support bracket, remove 3 attaching bolts on bottom of support bracket (Fig 4 ). While lowering support bracket, disconnect LDP wiring clip (Fig 5 ).
   Fig 4: Two-Piece Support Bracket

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   Fig 5: LDP Removal/Installation

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10. Remove hose clamp (Fig 6 ) and remove fuel fill hose from fuel fill tube.
11. Cut and discard tie wrap from axle vent hose (Fig 6 ).
12. Disconnect fuel vent hose from fuel vent tube (Fig 6 ).
    Fig 6: Fuel Fill Tube/Hose/Clamp

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13. Disconnect ORVR hose elbow (Fig 7 ) at top of EVAP canister.
    Fig 7: ORVR Hose Elbow

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14. Place hydraulic jack to bottom of fuel tank.
15. Remove fuel tank-to-rear bumper fascia clips (Fig 8 ).
    Fig 8: Bumper Fascia Clips

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16. Remove fuel tank heat shield mounting bolts (Fig 9 ).
    CAUTION: To protect fuel tank from exhaust heat, shield must reinstalled after tank installation.
    Fig 9: Fuel Tank Heat Shield Bolts

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WARNING: PLACE SHOP TOWEL AROUND FUEL LINES TO CATCH ANY EXCESS FUEL.
Fig 10: Fuel Filter/Fuel Pressure Regulator
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17. Disconnect fuel return line at fuel filter/fuel pressure regulator (Fig 10 ). Refer to QUICK CONNECT FITTING  for procedures.
18. Disconnect fuel pressure line at fuel filter/fuel pressure regulator (Fig 10 ). Refer to QUICK CONNECT FITTING  for procedures.
19. Disconnect EVAP canister vent line near front of tank (Fig 10 ).
20. Disconnect fuel pump module electrical connector (pigtail harness) near front of tank (Fig 10 ). Harness connector is clipped to body.
21. Remove left/front tank support bracket bolt at frame (Fig 11 ).
    Fig 11: Front Tank Support Bracket

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22. WITHOUT TRAILER HITCH:  Remove tank-to-frame mounting bolts (Fig 12 ). Remove rear tank support bracket bolt at frame (Fig 13 ). Carefully lower tank until clear of vehicle. Place tank on floor.
    Fig 12: Fuel Tank Mounting - No Trailer Hitch

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    Fig 13: Rear Tank Support Bracket

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23. WITH TRAILER HITCH:  Remove tank/hitch mounting bolts (Fig 14 ). Carefully lower tank until clear of vehicle. Place tank on floor.
    Fig 14: Fuel Tank Mounting - With Trailer Hitch

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24. If necessary, separate skid plate from fuel tank by removing 2 fuel tank strap nuts (Fig 12 ) and remove 2 tank straps.
25. If fuel pump module removal is necessary, refer to REMOVAL  .
26. If hoses are to be removed at fuel tank end, note painted alignment (indexing) markings on hoses, and molded indexing tangs on tank before removal. Remove hoses.
27. If necessary, remove 3 fuel filler tube assembly mounting bolts (Fig 15 ) and remove fuel filler tube.
    Fig 15: Fuel Filler Tube

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