Fuel Tank Replacement (Diesel)

Fuel Tank Replacement (Diesel)

Removal Procedure






Caution: Refer to Battery Disconnect Caution.

1. Disconnect the negative battery cable.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise the vehicle. Refer to Vehicle Lifting.
4. Disconnect the fuel fill hose (1) from the fuel tank.
5. Disconnect the fuel fill vent hose (2) from the fuel filler neck and cut the tie straps.
6. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
7. Disconnect the rear fuel return pipe at the chassis fuel return pipe.
8. Disconnect the rear fuel feed pipe at the chassis fuel feed pipe.
9. Disconnect the auxiliary heater fuel feed pipe.




10. With the aid of an assistant, support the fuel tank.
11. Remove the attaching bolts (4) from the fuel tank strap. Discard attaching bolts.
12. Remove the fuel tank straps (3).
13. Carefully lower the fuel tank.
14. Disconnect the fuel sender harness connector.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.




17. Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank.
18. On all models, remove the fuel fill hose from the fuel tank.
19. Remove the fuel tank from the fuel tank shield.

Installation Procedure




1. Install the fuel tank insulators (3).
2. Install the fuel tank into the fuel tank shield.

Notice: Refer to Fastener Notice.

3. Install the fuel fill hose to the fuel tank.

Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).

4. Install the (EVAP) hoses to the fuel tank and (EVAP) canister.
5. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter.




6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the fuel sender harness connector.
9. Raise the tank fully.
10. Install the fuel tank straps (3).

Important: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.

11. Install the new attaching bolts (4) to the fuel tank straps.

Tighten the bolts to 20.5 N.m (15 lb ft).

12. Connect the auxiliary heater fuel feed pipe.
13. Connect the rear fuel feed pipe to the chassis fuel feed pipe.
14. Connect the rear fuel return pipe to the chassis fuel return pipe.




15. Connect the fuel fill vent hose (2) to the filler neck.
16. Connect the fuel fill hose (1) to the fuel fill pipe.

Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).

17. Lower the vehicle.
18. Refill the fuel tank.
19. Tighten the fuel filler cap.
20. Connect the negative battery cable.
21. Prime the fuel system. Refer to Fuel System Priming.