Fuel tank wont come out

SECTION 310-01: Fuel Tank and Lines 2006 Freestyle/Five Hundred/Montego Workshop Manual REMOVAL AND INSTALLATION

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

1. Release the fuel system pressure. For additional information, refer to Section 310-00 .

1. Drain the fuel tank. For additional information, refer to Section 310-00 .

All wheel drive vehicles

1. Remove the rear driveshaft. For additional information, refer to Section 205-00 .

All vehicles

1. Remove the muffler. For additional information, refer to Section 309-00 .

1. Disconnect the fuel vapor control tube assembly valve-to-fuel vapor tube quick connect coupling. For additional information, refer to Section 310-00 .

1. Disconnect the fuel supply tube-to-fuel filter quick connect coupling. For additional information, refer to Section 310-00 .

1. Disconnect the fuel vapor tube-to-fuel vapor control tube assembly valve quick connect coupling. For additional information, refer to Section 310-00 .

1. Disconnect the fuel tank wiring harness electrical connector at the rear of the fuel tank.

1. Release the clamp and remove the fuel tank filler hose from the fuel tank.

1. Place a suitable lifting device under the fuel tank.

1. Remove the 2 front fuel tank strap bolts.
   • To install, tighten to 35 Nm (26 lb-ft).

1. NOTE: Do not bend the fuel tank straps.
   Loosen the 2 rear fuel tank strap bolts and position the 2 fuel tank straps aside.

1. Lower the fuel tank enough to move forward, clear of the fuel straps then complete the lowering procedure.

1. To install, reverse the removal procedure.

Procedure revision date: 08/19/2009

First of all, there is a recall for gas tank replacement for your vehicle. The dealer will replace it free. The link will get you to the document in PDF form
Redirect Notice
It looks like there is a bracket on one end of the tank hidden by a heat shield

FUEL SUPPLY SYSTEM Fits Buick Rendezvous

Tank Assembly REMOVAL & INSTALLATION CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury. 1988 Vehicles Fig. 1: Fuel tank mounting components
Fig. 2: Fuel tank insulator mounting positions

1. Disconnect the negative battery cable.
2. Properly relieve the fuel system pressure, as outlined earlier in this section.
3. Raise and safely support the vehicle.
4. Use a suitable hand operated pump device to drain the fuel through the filler tube into an approved container. CAUTION
   Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.
   
5. Support the fuel tank with a suitable jack.
6. Remove the 2 bolts securing the fuel tank straps, then swing the straps out of the way.
7. Lower the fuel tank enough to disconnect the vapor hose from the fuel sender assembly and the vapor hose from the vapor pipe at the rear of the fuel tank.
8. Detach the electrical connector from the fuel sender assembly and remove the two retaining clips. If equipped, disconnect the ground strap.
9. Disconnect the fuel filler and vent hoses from the fuel tank.
10. Remove the tank from the vehicle, slowly to ensure all connections and hoses have been disconnected. To install:
    
11. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
12. Position the fuel tank under the vehicle and raise the tank with a suitable jack.
13. Connect the fuel feed and return lines to the sender assembly.
14. Attach the electrical connector to the fuel sender assembly. If equipped, connect the ground strap.
15. Raise the tank into position into the vehicle and swing the mounting straps under the tank.
16. Install the front fuel tank strap mounting bolts and tighten to 35 ft. lbs. (47 Nm).
17. Remove the jack.
18. Connect the fuel filler and vent hoses to the tank.
19. Carefully lower the vehicle, then refill the fuel system
20. Connect the negative battery cable, then install the fuel filler cap, if not done already.
21. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.

1989–94 Vehicles

1. Disconnect the negative battery cable.
2. Properly relieve the fuel system pressure, as outlined earlier in this section.
3. Raise and safely support the vehicle. CAUTION
   Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.
   
4. Use a suitable hand operated pump device to drain the fuel through the filler tube into an approved container. NOTE: Before disconnecting any fuel lines from the fuel tank, thoroughly clean around all hose connections.
   
5. Disconnect the fuel filler vent hose from the fuel tank.
6. Detach the fuel filler hose from the fuel filler inlet tube on the fuel tank. Position the hose out of the way.
7. Disconnect the vapor hose from the front of the fuel tank.
8. Detach the fuel return pipe and position the hose out of the way.
9. Disconnect the two rear rubber exhaust hangers from the rear of the exhaust system and allow the exhaust system to hang down slightly.
10. Unfasten the exhaust shield mounting bolts, then remove the exhaust shield.
11. Support the fuel tank with a suitable jack.
12. Remove the two bolts securing the fuel tank straps, then swing the straps out of the way.
13. Lower the fuel tank enough to disconnect the vapor hose from the fuel sender assembly and the vapor hose from the vapor pipe at the rear of the fuel tank.
14. Detach the electrical connector from the fuel sender assembly and remove the two retaining clips.
15. Remove the tank from the vehicle, slowly to ensure all connections and hoses have been disconnected. To install:
    
16. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
17. Position the fuel tank under the vehicle and raise the tank with a suitable jack.
18. Connect the vapor hose to the fuel tank at the vapor pipe at the rear of the tank and connect the vapor hose to the sender assembly.
19. Attach the electrical connector to the fuel sender assembly.
20. Connect the fuel feed and return lines to the sender assembly.
21. Raise the tank into position into the vehicle and swing the mounting straps under the tank.
22. Install the front fuel tank strap mounting bolts and tighten to 35 ft. lbs. (47 Nm).
23. Remove the jack.
24. Connect the fuel return pipe to the fuel feed pipe.
25. Attach the rear fuel feed pipe to the inlet side of the fuel filter.
26. Tighten the line fittings to 16 ft. lbs. (22 Nm). Make sure to use a back-up wrench to prevent the fuel filter from turning.
27. Connect the vapor hose to the vapor pipe at the front of the vehicle.
28. Attach the fuel filler vent hose to the tank. Connect the fuel filler hose to the fuel filler neck of the tank.
29. Install the exhaust heat shield and the mounting bolts.
30. Position the exhaust system and install the rubber hangers.
31. Carefully lower the vehicle, then refill the fuel system
32. Connect the negative battery cable, then install the fuel filler cap, if not done already.
33. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.

Removal & Installation To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Shift the vehicle into NEUTRAL and position it on a hoist.
3. Release the fuel pressure.
4. Disconnect the negative battery cable.
5. Remove the fuel tank filler cap.
6. Drain as much fuel from the tank as possible.
7. Using suitable hose pinching pliers, clamp the fuel tank filler hose. Clamp the fuel tank filler hose in the location shown
   
   
8. Disconnect the three quick connect couplings from the fuel tank tubes at the tank.
9. Disconnect the fuel pump electrical connector.
10. Disconnect the fuel filter inlet tube from the filter.
11. Position a suitable lifting device under the fuel tank.
12. Remove the two fuel tank support strap bolts.
13. Lower the fuel tank to access the fuel pump module while swinging the fuel tank support straps away from the tank.
14. Clean the area around the fuel pump mounting flange.
15. Disconnect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
16. Using the special tool, turn the fuel pump module retaining ring counterclockwise and remove it. CAUTION
    The fuel pump module must be handled carefully to avoid damage to the float arm, filter and convolute hoses.
    
17. Turn the fuel pump module counterclockwise and the fuel pump module will release from the locking tabs. Remove the fuel pump module from the fuel tank.

To Install:

1. Install the fuel pump module in the fuel tank.
2. Connect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
3. Raise the tank into position and install the mounting strap bolts. Tighten the bolts to 26 ft-lbs (35 Nm).
4. Connect the fuel lines and electrical connectors at the fuel tank.
5. Lower the vehicle and refill the tank.
6. Connect the negative battery cable.
7. Turn the ignition key to the ON position to pressurize the fuel system.
8. Visually inspect the fuel system for leaks.

NOTE Always maintain cleanliness when servicing fuel system components.

1. Relieve the fuel system fuel pressure.
2. Drain the fuel tank.
3. Raise the vehicle.
4. Disconnect the fuel tank wiring harness connector at the body pass through.
5. For 3.4L engines, disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter.
6. For 3.4L engines, disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
7. Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
8. Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.
9. Remove the retaining nut for the EVAP canister bracket.
10. Loosen the fuel tank filler pipe hose clamp.
11. Disconnect the fuel tank filler pipe from the fuel tank.
12. For 3.5L engines, disconnect the EVAP vent pipe near the fill pipe hose.
    NOTE Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
    
13. With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts.
14. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
15. If the fuel tank is not being replaced, go to the Installation Procedure.
16. Disconnect the fuel tank wiring harness from the fuel sender assembly.
17. Remove the fuel sender shield from the fuel tank.
18. Disconnect the fuel feed and return pipe quick-connect fittings at the fuel sender.
19. Disconnect the EVAP vapor pipe assembly from the fuel sender.
20. Remove the fuel and/or EVAP pipe assembly from the fuel tank.
21. Remove the fuel sender assembly.
22. Remove the EVAP vent solenoid valve.
23. Remove the EVAP canister.

To install:

1. Install the EVAP canister.
2. Install the EVAP vent solenoid valve.
3. Install the fuel sender assembly.
4. Install the fuel and/or EVAP pipe assembly.
5. Connect the EVAP vapor pipe to the fuel sender assembly.
6. Connect the fuel feed and fuel return pipes at the fuel sender.
   NOTE Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
   
7. Install the fuel sender shield to the fuel tank and tighten the shield nuts to 53 inch lbs. (6 Nm).
8. Connect the fuel tank wiring harness to the fuel sender assembly.
9. With the aid of an assistant, position and support the fuel tank.
   NOTE Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
   
10. Install the fuel tank retaining strap attaching bolts and tighten the fuel tank retaining strap bolts to 35 ft. lbs. (47 Nm).
11. Install the EVAP canister retaining nut and tighten the retaining nut to 53 inch lbs. (6 Nm).
12. Connect the fuel tank filler pipe to the fuel tank and tighten the fuel tank filler pipe hose clamp to 22 inch lbs. (2.5 Nm).
13. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
14. Connect the fuel return pipe quick-connect fitting near the fuel filter.
15. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
16. Connect the fuel tank wiring harness connector at the body pass-through.
17. Lower the vehicle.
18. Add fuel and reinstall the fuel tank filler pipe cap.
19. Connect the negative battery cable.
20. Inspect for fuel leaks with the following procedure:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.

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Removal & Installation

1. Disconnect the negative battery cable and relieve the fuel system pressure.
   
2. Siphon or pump as much fuel as possible out through the fuel filler pipe.
   

Fuel injected vehicles have reservoirs inside the fuel tank to maintain fuel near the fuel pick-up during cornering or low-fuel operation. These reservoirs could block siphon hoses or tubes from reaching the bottom of the fuel tank. Repeated attempts, using different hose orientations, can overcome this obstacle.

1. Raise and safely support the vehicle.
   
2. If equipped, remove the skid plate attaching bolts, then lower the plate and remove it.
   

On Explorer/Mountaineer models, the front fuel tank strap is bolted to the skid plate and will be disconnected when the plate is removed.

1. Disconnect the fuel fill and vent hoses connecting the filler pipe to the tank.
   
2. On vehicles equipped with a metal retainer fastening the filler pipe to the fuel tank, remove the screw holding the retainer to the fuel tank flange.
   
3. Disengage the fuel lines and the electrical connections to the fuel tank sending unit/fuel pump assembly. On some vehicles, these are inaccessible on top of the tank. In this case, they must be disconnected when the tank is partially lowered.
   
4. Place a safety support (such as a floor jack) under the fuel tank and remove the bolts from the fuel tank straps. Allow the straps to swing out of the way. Be careful not to deform the fuel tank.
   

On Ranger vehicles, the rear fuel tank strap has two connections which must be unbolted.

1. Lower the tank a few inches, then detach the fuel lines and electrical connection from the sending unit/fuel pump assembly, if required.
   
2. Remove the tank from the vehicle.
   

To install:

1. Before installation, it would be wise to perform the following:
   
   1. Double-check the tightness of the sending unit/fuel pump locking ring. If it is already loose, now would be a good time to remove it and check the condition of the gasket underneath.
      
   2. Ensure that all metal shields are reinstalled in their original positions and that the fasteners are secure.
      
   3. Be sure that the fuel vapor valve is completely installed on top of the fuel tank.
      
   4. Make all necessary fuel line or wiring connections which will be inaccessible after the fuel tank is installed.
      
2. Raise the fuel tank into position in the vehicle. If necessary, attach the fuel lines and sending unit electrical connector before the tank is in its final position.
   
3. Lubricate the fuel filler pipe with a water-based lubricant. Install the tank onto the filler pipe, then bring the tank into final position. Be careful not to deform the tank.
   
4. Position the tank straps around the tank and start the retaining nut or bolt. Align the tank with the straps. If equipped, be sure the fuel tank shields are installed with the straps and are positioned correctly.
   
5. Check the hoses and wiring on top of the tank. Make sure they are correctly routed and will not be pinched between the tank and body.
   
6. Tighten the fuel tank strap retaining nuts or bolts to 20-5 ft. lbs. (3-41 Nm).
   
7. If not already attached, connect the fuel hoses and lines. Make sure the fuel supply, fuel return (if present) and the vapor vent attachments are made properly. If not already attached, connect the sending unit.
   
8. If removed, install the fuel tank skid plate.
   
9. Lower the vehicle.
   
10. Fill the tank with fuel and check all connections for leaks.
    

is fuel pump in tank? if so pump may have stopped working

After removing all connections and wiring from the tank and the sending unit and depressurize fuel system and drain the fuel tank and most importantly TO DISCONNECT THE BATTERY this is what you have to do :
1- Make sure to mark the wires for the sending unit so that you do not have a problem connecting in the correct place. 2- Remove bolts securing spare wheel mounting bracket and remove bracket. 3- Remove tank upper insulation pad. 4- Disconnect fuel pump harness from evaporative loss flange connection 5- Release harness attached to tank retaining straps and reposition harness downward. 6- Disconnect vapor pipe assembly from underbody pipe. 7- Push back collars on quickfit connectors and remove vapor pipe and over-pressure pipe from evaporative loss flange port. 8- Remove bolts securing tank retaining straps. 9- reposition straps upwards for access. 10- Remove strap holding filler housing solenoid block connector to harness and disconnect connector. 11- Disconnect drain tube from aperture seal (small pipe beside big one) 12- Open filler cap and remove filler neck garter spring. 13- Remove filler housing bolts. 14- Displace filler housing from body opening 15- Remove fuel tank. 16- Remove hose from evaporative loss flange and filler neck , ( Bend weld tag upwards to release hose). 17- Remove evaporative loss flange lock ring. 18- Lift flange from tank enough to disconnect fuel pump harness. 19- Remove flange and seal. 20- Inside tank , loosen hose clamps and remove fuel hoses from fuel pump module. 21- Remove fuel pump module and mounting rubber , note position of mounting rubber lugs. 22- Loosen hose clamps and remove two fuel hoses inside tank. 23- Remove tank sending unit. 24- Remove magnetic drain plug and make sure that you clean it well.
That is it your tank is out , and make sure that you mark every thing that you disconnected to install back in its proper place.
If you need any more help please let me know

1. Properly drain the fuel tank, then disconnect the negative battery cable.
2. If not done already, raise and support the rear of the truck safely using jackstands.
3. If equipped on late-model vehicles, loosen and remove the tank plastic shield.
4. Loosen the retaining clamp and disconnect the tank filler hose from the tank neck.

If fuel and vapor hoses or pump/sending unit wiring can be accessed at this time, they may be tagged and disconnected. If not, wait for the retaining straps to be loosened and lower the tank slightly for access.

1. Tag and disconnect and accessible wiring or hoses from the top of the fuel tank.
2. Have and assistant support the fuel tank, then remove the fuel tank-to-vehicle straps and, if equipped, the isolation strips. If no assistant is available, position a floor jack to support the tank while the straps are removed.
3. Lower the tank slightly, then remove the sending unit or sending unit/pump wires, hoses and ground strap. Be sure to label all connections to ease installation.
4. Carefully lower the fuel tank from the vehicle and store in a safe place.

To install:

1. Raise the tank partially into position in the vehicle. If you are working without an assistant, you may wish to loosely install one of the retaining straps and use a floor jack to support the tank at an angle so there is access to the sending unit or sending unit/pump assembly (as applicable).
2. Connect the fuel/vapor hoses and wiring to the top of the fuel tank, as tagged during removal.
3. Carefully raise the fuel tank so it is fully into position and loosely secure the retaining straps. Make sure the wires and hoses are not pinched or damaged when raising the tank. Also, be sure that the isolation strips (if used) are positioned between the retaining straps and the fuel tank.
4. It may be easier to connect the fuel filler hose to the tank neck at this time. If desired, connect the hose and secure the clamp.
5. Tighten the fuel tank retaining strap fasteners to specification. Tighten the strap nuts to 33 ft. lbs. (45 Nm).
6. If not done earlier, connect the tank filler hose to the tank neck and secure using the clamp.
7. If equipped, install and secure the tank plastic shield.
8. Remove the jackstands and carefully lower the rear of the truck.
9. Refill the fuel tank and install the filler cap, then check for leaks.
10. Connect the negative battery cable.

Equipped With Shield Package

1. Properly drain the fuel tank, then disconnect the negative battery cable.
2. Raise and support the rear of the truck safely using jackstands.
3. Remove the shield forward support and bracket.
4. While supporting the shield and tank assembly with the help of both an assistant and a floor jack, remove the remaining bolts holding the assembly to the frame, then lower it sufficiently for access to the hoses and wires.
5. Tag and disengage the hoses and wires from the sending unit assembly.
6. Carefully lower the fuel tank and shield from the vehicle, then if necessary for service or replacement, separate the tank from the shield.

To install:

1. If separated, install the tank to the shield.
2. Carefully raise the tank and shield assembly partially into position with the help of an assistant and a floor jack.
3. Connect the wiring and hoses to the sending unit assembly, as tagged during removal.
4. Raise the tank and shield assembly fully into position, then secure to the frame using the lower retaining bolts.
5. Install the shield forward support bracket.
6. Remove the jackstands and carefully lower the rear of the truck.
7. Refill the fuel tank and install the filler cap, then check for leaks.
8. Connect the negative battery cable.

  any question I can send some diagrams