Fuel Tank - Motorhome Chassis

Fuel Tank - Motorhome Chassis

Special Service Tool(s):

Special Service Tool(s)

Removal

WARNING: Do not smoke or 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 may be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

1. Disconnect the battery ground cable.
2. Relieve the fuel pressure.
3. Drain the fuel from the fuel tank.
4. Raise and support the vehicle.






5. Disconnect the fuel tank filler pipe and the filler vent tube.
6. Position the jack under the fuel tank.






7. Remove the eight bolts from the RH frame rail.






8. Remove the bolts from the LH frame rail.
9. Partially lower the fuel tank.
10. Disconnect the fuel lines from the fuel pump.






11. Disconnect the fuel pump and fuel tank sending unit electrical connector.






12. Disconnect the hose(s) from the evaporative emission valve.






13. Disconnect the fuel tank pressure sensor electrical connector.
14. Lower the fuel tank.
15. If the fuel tank is being replaced, transfer the fuel pump, fuel tank sending unit, the evaporative emission valves and the fuel tank pressure sensor to the new fuel tank.






16. Remove the eight fuel tank strap nuts, and remove the fuel tank from the cradle.
17. Remove the fuel tank straps from the fuel tank cradle brackets.

Installation
1. Position a new fuel tank in the cradle brackets.






2. CAUTION: Steps 2-4 must be followed to prevent damage to the fuel tank.

Install the fuel tank straps and tighten the RH nuts with four threads showing.






3. Tighten the LH fuel tank strap nuts.
4. Position the fuel tank sub-assembly below the frame rail.






5. NOTE: The fuel tank must be loose in the cradle for proper positioning.

Tighten eight fuel tank strap nuts.






6. Connect the fuel tank pressure sensor electrical connector.






7. Connect the hose at the evaporative emission valve.






8. Connect the fuel pump and fuel tank sending unit electrical connector.






9. Tighten the eight RH bolts.






10. Tighten the eight LH bolts.
11. Connect the fuel lines at the fuel pump.






12. Connect the fuel tank filler pipe and the filler vent tube.
13. Lower the vehicle.
14. Connect the battery.