ION, L-Series, S-Series 1999-2005

Removal & Installation

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  1. Relieve the fuel system pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Disconnect the fuel feed and return lines from the fuel filter.
  8.  
  9. Cap or plug the fuel tank feed and return pipes to prevent fuel loss and/or contamination. Disconnect the EVAP purge pipe from the EVAP canister and fuel tank EVAP vapor pipe (3) from the EVAP canister
  10.  
  11. Cap or plug the EVAP purge and vapor pipes to prevent contamination.
  12.  
  13. Loosen the fuel filler hose clamp at the fuel tank.
  14.  
  15. Disconnect the fuel filler hose from the fuel tank.
  16.  
  17. Disconnect the fuel pump module harness electrical connector from the vehicle underbody connector.
  18.  
  19. Release the exhaust extension pipe insulators from the underbody hangers.
  20.  
  21. Release the muffler insulator from the underbody hanger and slowly lower the exhaust to rest on the rear axle beam.
  22.  
  23. Have an assistant support the fuel tank during fuel tank strap removal, and during tank removal.
  24.  
  25. Remove the left hand fuel tank strap bolts and the strap.
  26.  
  27. Remove the right hand tank strap bolts and the strap.
  28.  
  29. In order to clear the exhaust extension pipe, slowly lower the right hand side of the fuel tank. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness to clear the axle.
  30.  
  31. Once the tank is clear of the right hand frame rail, remove the fuel tank down and toward the right hand side of the vehicle.
  32.  
  33. If the fuel tank only is to be replaced, remove the fuel pump module assembly from the fuel tank. Refer to
  34.  

To install:

  1. If fuel tank replacement was necessary, install the fuel pump module assembly to the fuel tank.
  2.  
  3. Have an assistant support the fuel tank during fuel tank and fuel tank strap installation.
  4.  
  5. Begin to install the left hand side of the fuel tank over the exhaust pipe.
  6.  
  7. Raise the right hand side of the fuel tank into position inboard of the right hand frame rail.
  8.  
  9. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness over the rear axle.
  10.  
  11. Install the right hand fuel tank strap and strap bolts.
  12.  
  13. Install the left hand fuel tank strap and strap bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  14.  
  15. Install the remaining components in the reverse order of removal.
  16.  
  17. Turn the ignition on for 2 seconds and off for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on but do not start the engine. Start the engine and check for leaks.
  18.  

 
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