Fuel Tank - Aft-of-Axle

Fuel Tank - Aft-of-Axle

Removal and Installation

All vehicles

WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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 serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Release the fuel system pressure.

3. Disconnect the battery ground cable.

4. Drain the fuel tank.

5. Disconnect the fuel tank filler pipe and the filler vent tube from the fuel tank.





6. Position a suitable jack under the fuel tank.

7. NOTE: The 151L (40 gal) fuel tank has 2 cradle bracket bolts and the 208L (55 gal) has 3 cradle bracket bolts.

Remove the 2 or 3 fuel tank cradle bracket bolts.

- To install, tighten to 103 Nm (76 lb-ft).

8. NOTE: The 151L (40 gal) fuel tank has 2 cradle bracket nuts and the 208L (55 gal) has 3 cradle bracket nuts.

Remove the 2 or 3 fuel tank cradle bracket nuts.

- To install, tighten to 90 Nm (66 lb-ft).

9. NOTE: The 151L (40 gal) fuel tank has 2 fuel tank support strap nuts and the 208L (55 gal) has 3 fuel tank support strap nuts.

Remove the 2 or 3 nuts and the fuel tank support straps.

10. Partially lower the fuel tank.

Gasoline engines

11. Disconnect the fuel vapor tube-to-fuel vapor vent valve(s) quick connect coupling(s).

12. Disconnect the fuel supply tube-to-Fuel Pump (FP) module quick connect coupling.

13. Disconnect the FP module and Fuel Tank Pressure (FTP) sensor electrical connectors.

Diesel engine

14. Disconnect the fuel supply tube and fuel return tube to fuel level sensor quick connect couplings.

15. Disconnect the fuel level sensor electrical connectors.

All vehicles

16. Lower the fuel tank.

17. To install, reverse the removal procedure.