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Fuel Tank: Installation

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 ORVR COMPONENTS FOR DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
  1. If necessary, position fuel filler tube assembly to body. Install 3 bolts. Refer to TORQUE - FUEL DELIVERY  .
  2. If necessary, connect quick-connect fittings to fuel pump module.
  3. If fuel pump module is being installed, refer to INSTALLATION  .
  4. Install fuel fill/vent hoses to tank fittings. To prevent hoses from kinking, rotate each hose until painted indexing mark on hose is aligned to molded indexing tang on tank.
  5. Install hose clamps to hoses. Refer to TORQUE - FUEL DELIVERY  .
  6. If necessary, position fuel tank into skid plate. Install 2 tank straps and 2 strap nuts (Figure ). Refer to TORQUE - FUEL DELIVERY  .
  7. Position fuel tank/skid plate assembly to hydraulic jack.
  8. Raise tank into position to frame.
  9. WITH TRAILER HITCH:  Position trailer hitch and tow hooks (Figure ) to bottom of fuel tank. Install bolts and nuts loosely.
  10. WITHOUT TRAILER HITCH:  Install 2 rear tank support brackets and bolts (Figure ). Install tank-to-frame bolts. Do not tighten bolts/nuts at this time.
  11. Install 1 left/front tank support bracket and bolts/nuts (Figure ). Do not tighten bolts/nuts at this time.
  12. Be sure fuel tank is properly aligned to frame and body. Tighten all tank, tow hook and trailer hitch bolts/nuts except for 3 support brackets. Tighten all 3 (2 rear and 1 left/front) support bracket bolts/nuts last. Refer to TORQUE - FUEL DELIVERY  .
  13. Connect fuel pump module pigtail harness electrical connector near front of tank.
  14. Connect both fuel lines to fuel filter/fuel pressure regulator. Refer to QUICK CONNECT FITTING  for procedures.
  15. Connect EVAP hose near front of tank.
  16. Position rear axle vent hose and install new tie strap (Figure ).
  17. Install heat shield nuts/bolts (Figure ). Refer to TORQUE - FUEL DELIVERY  .
  18. Connect ORVR hose elbow (Figure ) to top of EVAP canister.
  19. Connect fuel vent hose to fuel vent tube (Figure ).
  20. Install fuel fill hose and clamp to fuel fill tube (Figure ).
  21. Install 3 LDP mounting bolts (Figure ).
  22. While raising support bracket, connect LDP wiring clip (Figure ). Install front section of two-piece support bracket to rear section with 3 attaching bolts located on bottom of support bracket (Figure ).
  23. Install support bracket brace bolt (Figure ).
  24. Tighten 2 support bracket nuts at frame rail (Figure ).
  25. Install fuel tank-to-rear bumper fascia clips (Figure ).
  26. Using new plastic rivets, install stone shield behind left/rear wheel (Figure ).
  27. Install left rear wheel/tire.
  28. Lower vehicle and connect negative battery cable to battery.
  29. Fill tank with fuel and check for leaks.
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