Early Build
FUEL TANK AND FILLER PIPESpecial Tool(s):
SPECIAL 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. Failure to follow these instructions may result in personal injury.
- The evaporative emissions system contains fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground to minimize the possibility of an electrical spark occurring, possibly causing fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. When removing the fuel tank, it will be necessary to release the fuel system pressure.
4. 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.
When removing the fuel tank, it will be necessary to remove the driveshaft.
5. When removing the fuel tank, it will be necessary to release the fuel tank fill hose clamp and disconnect the fuel filler hose from the fuel filler pipe assembly.
6. When removing the fuel tank, it will be necessary to use the special tool and siphon the fuel through the lower fuel filler hose into a suitable container.
7. If equipped, remove the fuel tank skid plate.
1 Remove the three bolts at the outboard frame rail.
2 Remove the two nuts on the inboard side of fuel tank to the No. 3a and No. 3b frame crossmembers.
3 Remove the skid plate.
8. If equipped, remove the transfer case skid plate by removing the four bolts from the outer frame rail (two per side).
Part 1:
Part 2:
9. Remove the components in the order indicated in the illustration and table. To remove individual components, only carry out the listed steps.
Item 3: Vapor Snorkel Removal Note
1. Carefully twist and pull the vapor snorkel from the fuel filler pipe housing. This can be accessed through the wheelwell.
Item 4: Fuel Filler Tube Removal Note
1. This is a squeeze-type release clip.
Item 8: Fuel Line Retainer Clip Removal Note
1. Release the fuel line from the retainer clip mounted at the top rear of the fuel tank.
Item 10: Fuel Tank Filler Pipe Assembly Removal Note
1. The fuel tank filler pipe assembly is removed as a complete unit. Do not disassemble.
Item 11: Fuel Supply Line Removal Note
1. Remove the fuel filter shield.
1 Remove the two nuts.
2 Remove the shield.
2. Disconnect the safety clip.
3. Install the special tool and push it into the fitting.
4. Separate the fitting.
- Inspect the damage.
- Clean the fittings.
Item 12: Fuel Vapor Line Removal Note
1. This is a squeeze-type quick-release connector.
Item 19: Fuel Tank Removal Note
1. Use a suitable jack to support and lower the fuel tank.
2. Lower the tank enough to finish disconnecting the remaining hoses and electrical connectors then finish lowering.
Items 20 & 21: Quick-Connect Fitting Removal Note
1. Unclip the tab.
2. Depress the tap and press the clip downward.
3. Separate the fittings.
Item 22: Fuel Pump Lock Ring Removal Note
1. Install the special tool.
INSTALLATION
1. To install, reverse the removal procedure.
Item 24: Fuel Pump Gasket Installation Note
1. Install a new fuel pump mounting gasket seal.
Item 11: Fuel Supply Line Installation Note
1. Align the fuel line fitting and press together until a click is heard.
2. Pull on the fitting to make sure it is fully engaged. Install a safety clip.
Item 10: Fuel Tank Filler Pipe Assembly Filler Pipe Installation Note
1. The fuel tank filler pipe assembly is to be installed as a complete unit. Do not disassemble.