Fuel Tank Assembly

Fuel Tank:

WARNING: The water/diesel fuel mixture is flammable, and could be hot. To help avoid personal injury and/or property damage, do not touch the fuel coming from the drain hose, and do not expose the fuel to open flames or sparks. Be sure you do not overfill the container. Heat (such as from the engine) can cause the fuel to expand. If the container is too full, fuel could be forced out of the container. This could lead to a fire and the risk of personal injury and/or vehicle damage.

REMOVE OR DISCONNECT
1. Drain fuel tank refer to Draining Fuel Tank. Fuel Tank Draining
2. Raise vehicle.
3. Off road shield (if equipped).

Clean
- Clean all fuel pipe and hose connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.

4. Vent hose at fuel tank.
5. Filler tube connection at fuel tank.
6. With aid of an assistant, support tank, and remove fuel tank strap attaching bolts and retaining fuel tank straps and shield.

CAUTION: Do Not bend fuel tank straps, as this may damage straps.

- Lower tank enough to disconnect fuel sender electrical connector and remove the retaining clips.
- Hoses from fuel sender.
- Fuel tank from vehicle and place in a suitable work area.

DISASSEMBLE

- If fuel tank is not being replaced proceed to Install or Connect.
- Fuel sender refer to Fuel Sender Replacement. Service and Repair

ASSEMBLE

- Install fuel sender assembly with new O-rings on pipes refer to Fuel Sender Replacement. Service and Repair

INSTALL OR CONNECT
1. Position and support fuel tank. Position fuel tank straps with insulators and connect:

- Fuel feed and return hoses to fuel sender fittings.

Tighten
- Fuel feed and return hoses to sender pipe fittings to 22 Nm (16 lb. ft).

- Fuel sender electrical connector and install retaining clips.
- Fuel filler vent hose to vent pipe.
- Fuel filler neck connecting tube to fuel tank,
- Shield (if equipped).

Tighten
- Fuel tank strap bolts or nuts to 13 Nm (115 lb. in.).

2. Negative battery cable.
3. Bleed air from system. Refer to Bleeding Air from Fuel Supply System. Service and Repair
4. Start engine and check for leaks.