Tank, Fuel: Removal
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
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. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.
- Perform Fuel System Pressure Release Procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
- If possible, drain the fuel tank using the Conventional Procedure. Refer to DRAINING FUEL TANK .
- Disconnect and isolate the negative battery cable.
- Remove the fuel filler cap to relieve tank pressure.
- Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
- Disconnect the EVAP solenoid to vapor canister line quick-connect fitting (2). Refer to QUICK-CONNECT FITTINGS .
- Disconnect the fuel pump module to fuel rail line quick-connect fitting (1). Refer to QUICK-CONNECT FITTINGS
.
- Loosen the fuel filler tube hose clamp (3) and remove the fuel filler tube from the fuel tank.
- Disconnect the EVAP solenoid to vapor canister line quick-connect fitting (4). Refer to QUICK-CONNECT FITTINGS .
- Disconnect the On-Board Refueling Vapor Recovery (ORVR) vacuum line quick-connect fitting (2) from the ORVR control valve. Refer to QUICK-CONNECT FITTINGS .
- Disconnect the vapor canister line quick-connect fitting (1) from the ORVR control valve. Refer to QUICK-CONNECT FITTINGS
.
- Remove the transfer case skid plate (2). Refer to PLATE, SKID, TRANSMISSION, REMOVAL
.NOTE:
The fuel tank skid plate and the fuel tank assembly are removed at the same time. They share common fasteners.
- Position a support fixture under the fuel tank (3) such as OTC® Fuel Tank Handler 1758 on the OTC® High-Lift Transmission Jack 1728.
- Remove eight bolts (1) and partially lower the fuel tank to gain access to the fuel pump module electrical connector.
- Disconnect the electrical connector (2) from the fuel pump module (1).
- Continue lowering the fuel tank for removal.
- If required, lift the fuel tank from the skid plate.
- If required, remove the fuel pump module from the fuel tank. Refer to MODULE, FUEL PUMP, REMOVAL .