Fuel Tank Removal and Installation

REMOVAL

WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DRAINING FUEL TANK, FUEL SYSTEM PRESSURE MUST BE RELEASED.

Two different procedures may be used to drain fuel tank (through fuel tank vent tube fitting or using DRB scan tool).

The quickest procedure involves draining the tank through the vent fitting.

The electric fuel pump may be activated allowing fuel tank to be drained. This is done at fuel rail connection using DRB scan tool. Refer to scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure in this group for procedures. Attach end of special test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and drain tank until empty.

If electric fuel pump does not operate, fuel can be siphoned through fuel vent fitting at outer part of left frame rail. The fuel vent hose will have to be disconnected from tank vent fitting for this operation.
1. Disconnect negative battery cable at battery.
2. Remove fuel tank filler tube cap.
3. Perform Fuel System Pressure Release Procedure as described in this group.
4. Raise vehicle on hoist.

WARNING: WRAP SHOP TOWELS AROUND FUEL FILL AND VENT HOSES TO ABSORB ANY GASOLINE THAT MIGHT SPILL.

Fig.24 Fuel Tank Fill And Vent Nose Connections:

5. Disconnect fuel vent hose clamp from fuel vent hose at outer part of left frame (Fig. 24). Disconnect vent hose from tank fitting.
6. Install hose from an approved portable gasoline holding tank into vent fitting. Drain fuel from tank.
7. Disconnect fuel fill hose clamp from fuel fill hose at outer part of left frame (Fig. 24). Disconnect fill hose from tank fitting.
8. Support fuel tank securely to transmission jack.

Fig.25 Fuel Tank Mounting:

9. Disconnect tank mounting strap J-bolt nuts and remove fuel tank straps (Fig. 25).

The fill and vent fittings are permanently attached at the fuel tank end, and are not serviceable. They are routed through an access hole in the frame rail and protected by a plastic shield (Fig. 26). The fittings are snapped into this plastic shield. When lowering the fuel tank, caution must be used to prevent the fitting assembly from bending/kinking.

Fig.26 Disconnect/Connect Fill/Vent Hose Fittings At Plastic Shield:

10. Push 2 tabs inward to release fill/vent fittings from plastic shield (Fig. 26) before lowering tank.
11. Lower tank until connections can be accessed on top of tank. As tank is being lowered, carefully guide fill/vent fitting assembly through plastic shield and frame access hole.

Fig.27 Fuel Tank Connections - Typical:

12. Disconnect fuel supply tube (line) from fuel filter/fuel pressure regulator (Fig. 27). Refer to Quick-Connect Fittings in this section.
13. Disconnect fuel vapor line from both fuel tank check valve fittings.
14. Disconnect electrical connector at fuel pump module (Fig. 27).
15. If fuel pump module removal is necessary, refer to Fuel Pump Module Removal/Installation in this group for procedures.

INSTALLATION

WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DRAINING FUEL TANK, FUEL SYSTEM PRESSURE MUST BE RELEASED.

1. If fuel pump module is being installed, refer to Fuel Pump Module Removal/Installation in this group for procedures.
2. Place fuel tank on top of transmission jack and position under vehicle.
3. Raise tank until fuel supply line, electrical connector and rollover valves can be connected to fuel tank.
4. Connect fuel supply line to fuel filter/fuel pressure regulator. Refer to Quick-Connect Fittings in this section.
5. Connect pump module electrical connector.
6. Connect fuel vapor line to both fuel tank check valve fittings.
7. Continue raising tank while carefully guiding fuel fill/vent hose fittings through plastic shield and access hole in frame. Do not allow the fitting assembly to bend or kink while installing.
8. Snap fuel fill/vent fitting assembly into plastic shield.
9. Install tank straps, J-bolts and nuts. Tighten nuts to 7 Nm (60 in. lbs.) torque.
10. Connect fuel fill and vent hoses to tank fittings. Install new hose clamps of original type. Tighten clamps to 3 Nm (25 in. lbs.) torque.
11. Connect battery cable to battery
12. Fill fuel tank.
13. Install fuel tube filler cap.
14. Check for leaks.