Fuel tank — removal and installation
Warning: Before disconnecting or opening any part of the fuel system, relieve the fuel system pressure (see Fuel pressure relief procedure), and equalize the pressure inside the fuel tank by removing the fuel filler cap.
1. Relieve the fuel system pressure (see Fuel pressure relief procedure).
2. Disconnect the cable from the negative battery terminal (see Battery — disconnection and reconnection).
3. Raise the vehicle and support it securely on jack stands.
4. Remove the fuel tank rock guard, if equipped.
5. Locate the fuel tank filler neck hose (see illustration) and disconnect the filler neck hose from the tank pipe.
7.5 Loosen the hose clamp on the fuel tank filler neck hose (at the tank), then work the hose off the pipe
6. Locate the EVAP line that goes from the tank to the EVAP canister and disconnect it from the EVAP canister. Disconnect the EVAP vent line from the EVAP canister. Disconnect any EVAP line clips attaching the line to the chassis.
7. Locate the fuel line quick-connect fittings (see Fuel lines and fittings — general information and disconnection) and disconnect them from the chassis lines (see illustration).
7.7 Disconnect the fuel and EVAP line quick-connect fittings
8. It’s easier to remove the fuel tank when it’s nearly empty. But there is no fuel tank drain plug, so if there’s still a lot of fuel in the tank, siphon or hand-pump the remaining fuel, from the tank through the tank filler neck pipe, into an approved gasoline container.
Warning: Don’t start the siphoning action by mouth! Use a siphoning kit (available at most auto parts stores).
9. Detach any clips that secure the fuel pump/fuel level sending unit harness to the crossmember or frame rail and detach it/them.
Caution: Failure to detach these clips will result in damage to the fuel pump/fuel level sending unit harness when the tank is lowered.
10. Support the fuel tank.
11. The fuel tank is retained by two transverse straps. The outer end of each fuel tank strap is secured to the vehicle by a bolt (see illustrations). The inner end of each strap is secured to a mounting bracket by a hinge. Remove the two fuel tank strap bolts, then disengage each strap hinge from its mounting bracket and remove the straps.
7.11a To detach the fuel tank from the vehicle , remove the front fuel tank strap bolt …
7.11b. and the rear fuel tank strap bolt
12. Carefully lower the tank just far enough to access the fuel pump/fuel level sensor module, then disconnect the electrical connectors from the pump module and from the fuel tank fuel pressure sensor (see illustration).
7.12 To disconnect the electrical connector from the fuel pump/fuel level sending unit module, slide the connector lock out (A), then depress the tab (B) and pull off the connector. To disconnect the electrical connector from the fuel tank pressure sensor, depress the tab (C) and pull off the connector
13. Lower the tank the rest of the way.
14. Installation is the reverse of removal.