Fuel Tank: Service and Repair

REMOVAL
1. Drain diesel fuel from tank using an approved diesel fuel draining station.

Fuel Tank Assembly:

2. Disconnect fuel fill and vent lines from body.
3. Raise and support vehicle.
4. Support tank with a hydraulic jack.
5. Remove 2 fuel tank strap nuts and position straps towards left side of vehicle.
6. Carefully lower tank a few inches and disconnect electrical connector at top of fuel tank module.
7. Disconnect fuel supply line at tank.
8. Disconnect fuel return line at tank.
9. Continue to carefully lower tank for removal.
10. If fuel tank module is to be removed, thoroughly clean area at top of fuel tank around module.
11. If fuel tank is to be replaced, remove fuel tank module from tank. Refer to Fuel Tank Module REMOVAL/INSTALLATION procedures.

INSTALLATION
1. If fuel tank is to be replaced, install fuel tank module into tank. Refer to Fuel Tank Module REMOVAL/INSTALLATION procedures.
2. Position fuel tank to hydraulic jack.
3. Raise tank until positioned near body.
4. Connect fuel tank module electrical connector at top of tank.
5. Connect fuel supply and return lines.
6. Continue raising tank while guiding fill hose into body. Raise tank until positioned snug to body.
7. Install and position both fuel tank support straps to mounting studs.
8. Install 2 fuel tank strap nuts. Refer to Torque Specifications.
9. Remove hydraulic jack.
10. Connect fill and vent hoses to body. Install ground wire to fill hose.
11. Lower vehicle.
12. Fill fuel tank with fuel.
13. Start engine and check for fuel leaks near top of module.