FUEL TANK DRAINING Special Tool(s) Zoom Special Tool(s) WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. If equipped, turn the air suspension switch OFF. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Release the fuel system pressure. 4. Disconnect the battery ground cable.
Zoom 5. Disconnect the fuel tank filler pipe from the fuel tank. Zoom 6. NOTE: Follow the operating instructions of the equipment manufacturer. Using the special tool, pump the fuel from the fuel tank opening into the fuel storage tank. FUEL TANK Part 1
Zoom Part 2
Zoom Exploded View Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. Fuel in the fuel system remains under high pressure even when the engine is not
CAUTION: running. Before servicing or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Failure to follow these instructions may result in personal injury. Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3. Drain the fuel tank. 4. If equipped, remove the 4 nuts and the fuel tank skid plate. To install, tighten to 20 Nm (15 lb-ft). 5. Disconnect the 2 vapor tubes at the rear of the fuel tank. 6. Disconnect the vapor tube and the fuel filter outlet tube forward of the fuel tank. 7. Disconnect the vapor tube from the evaporative emissions (EVAP) system dust separator. Zoom 8. CAUTION: Do not support the fuel tank directly beneath the fuel pump
mounting area. Damage to the fuel pump assembly can occur. Position a suitable jack under the fuel tank. 9. NOTE: The location of the fuel vent hose is critical to fuel system operation. Note the routing of the fuel vent hose at this time. Remove the 2 bolts and the fuel tank front and rear support straps. Lower the front of the fuel tank approximately 25 mm (1 in). To install, tighten to 40 Nm (30 lb-ft). 10. Disconnect the vent tube from the fuel pump module. 11. Disconnect the fuel pump module and fuel pressure transducer electrical connectors. 12. Remove the fuel tank from the vehicle. 13. To install, reverse the removal procedure. Fuel Tank 28.0 gallons (106 liters) WARNING: ADHERE TO THE FOLLOWING PROCEDURES ANY TIME THE FUEL SYSTEM IS BEING WORKED ON IN ORDER TO REDUCE THE RISK OF FIRE AND PERSONAL INJURY Keep a dry chemical (Class B) fire extinguisher near the work area. Place a "CAUTION FLAMMABLE" sign in the work area. Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. Wear eye protection. Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) Relieve the fuel system pressure prior to disconnecting fuel system components. Disconnect the negative battery cable except for tests where battery voltage is required. Use a suitable container to store or catch fuel. Do not replace fuel pipe with fuel hose. Plug all disconnected fuel line fittings and hoses. After making any fuel system repairs ALWAYS inspect for fuel leaks. Fuel Tank Part OEM Part Price Fuel Tank 5L1Z9002AA $478.42 Notes Labor Skill Mfg. Level Warranty Standar d
Fuel Tank Replace B 1.8 2.7 Notes Does Not Include: Drain & Refill Fuel Tank.