Fuel Tank Replacement (1500 SWB - 98.4L (26 Gal) Tank)

FUEL TANK REPLACEMENT (1500 LWB - 98.4L (26 gal) TANK)

TOOLS REQUIRED
J 45722 Fuel Sender Lock Ring Wrench

REMOVAL PROCEDURE

IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Drain the fuel tank. Refer to Fuel Tank Draining (Dual Tanks - Front) Fuel Tank Draining (Dual Tanks - Rear) Fuel Tank Draining (Single Tank).
3. Disconnect the fuel tank vent line quick connect fitting (5) from the fuel fill pipe line.




4. Disconnect the chassis EVAP line quick connect fitting (4) from the fuel tank line.
5. Disconnect the fuel tank fuel feed line quick connect fitting (5) from the chassis line.
6. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.




7. Disconnect the fuel tank EVAP lines (1) from the EVAP canister.
8. Cap the EVAP lines in order to prevent possible EVAP system contamination.
9. Using an adjustable jack, support the fuel tank.
10. Remove the fuel tank strap bolts.

11. NOTE: Refer to Damage to Fuel Tank Straps Notice.

Remove the fuel tank straps.
12. With the aid of an assistant, carefully lower the rear of the fuel tank.
13. Slide the front of the tank away from the frame.
14. Lower the fuel tank slightly until the chassis wiring harness electrical connectors can be accessed.




15. Disengage the chassis wiring harness electrical connector, connector position assurance (CPA) retainer at the module.
16. Disconnect the chassis wiring harness electrical connectors (1) from the module and the fuel pressure sensor.




17. Completely lower the fuel tank.
18. With the aid of an assistant, place the fuel tank in a suitable work area.
19. If replacing the fuel tank proceed to the next step, otherwise proceed to step 18 in the installation procedure.




20. Remove the fuel feed line from the retaining feature (2) in the fuel tank.
21. Open the fuel/EVAP line clip (1) and remove the fuel feed line from the clip.
22. Disconnect the fuel feed line quick connect fitting at the fuel tank module.




23. Remove the fuel feed line from the fuel tank.




24. Remove the fuel tank shield retainers (2 and 3) and shields (1 and 4).




25. Remove the EVAP line from the fuel tank clips (2 and 6).
26. Open the fuel tank clips (1, 3, 4, and 5) and remove the EVAP lines from the clips.
27. Disconnect the EVAP line quick connect fittings at the fuel tank module and fuel tank vent valve.




28. Remove the EVAP lines from the fuel tank.




29. Using the J 45722, remove the lock ring.




30. Carefully lift the module from the fuel tank, enough to access the quick connect fittings (1) under the module cover. Disconnect the quick connect fittings.
31. Remove the fuel tank module.
32. Remove and discard the fuel tank module seal.

33. IMPORTANT:
- Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.
- Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
- Check the lock ring for flatness.




Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
34. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
35. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

INSTALLATION PROCEDURE




1. If the fuel tank was replaced perform the following steps, otherwise proceed to step 18.
2. Install the NEW fuel tank module seal onto the fuel tank.
3. Pull the vent lines in the fuel tank up as far as possible for ease of installation.
4. Position the fuel tank module part way into the fuel tank.
5. Connect the quick connect fittings (1) to the module cover.
6. Install the fuel tank module into the fuel tank.
7. Place the lock ring into position.

8. IMPORTANT:
- Always replace the fuel module seal when installing the fuel module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.
- Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.




Rotate the lock ring counterclockwise using the J 45722.




9. Install the EVAP lines to the fuel tank.




10. Connect the EVAP line quick connect fittings at the fuel tank module and fuel tank vent valve.
11. Install the EVAP lines to the fuel tank clips (1, 3, 4, and 5) and close the clips.
12. Install the EVAP line to the fuel tank clips (2 and 6).




13. Install the fuel tank shields (1 and 4) and retainers (2 and 3).




14. Install the fuel feed line to the fuel tank.




15. Connect the fuel feed line quick connect fitting at the fuel tank module.
16. Install the fuel feed line to the clip (1) and close the clip.
17. Install the fuel feed line to the retaining feature (2) in the fuel tank.




18. Place the fuel tank onto a suitable jack.
19. With the aid of an assistant, partially raise the fuel tank until the electrical connections can be made.
20. Connect the chassis wiring harness electrical connectors (1) to the fuel tank module and fuel pressure sensor.
21. Engage the chassis harness electrical connector CPA retainer at the module electrical connector.




22. Completely raise the fuel tank.
23. Install the fuel tank straps.

24. NOTE: Refer to Fastener Notice.

Install the fuel tank strap bolts.

Tighten the bolts to 40 N.m (30 lb ft).

25. Remove the adjustable jack from the fuel tank.




26. Remove the caps from the EVAP lines.
27. Connect the fuel tank EVAP lines (1) to the EVAP canister.




28. Remove the caps from the fuel and EVAP lines.
29. Connect the chassis EVAP line quick connect fitting (4) to the fuel tank line.
30. Connect the fuel tank fuel feed line quick connect fitting (5) to the chassis line.




31. Connect the fuel tank vent line quick connect fitting (5) to the fuel fill pipe line.
32. Install the fuel fill hose to the fuel tank. Ensure that the notch in the hose is aligned with the notch on the fuel tank.
33. Install the fill pipe bracket bolts (2 and 3).

Tighten the bolts to 12 N.m (106 lb in).

34. Tighten the fuel fill hose clamp (1).

Tighten the clamp to 2.5 N.m (22 lb in).

35. Lower the vehicle.
36. Refill the fuel tank.
37. Install the fuel fill cap.
38. Connect the negative battery cable.
39. Use the following procedure in order to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.
40. Install the intake manifold sight shield.