Draining Fuel Tank

REMOVAL

1. Drain diesel fuel from tank using an approved diesel fuel draining station.
2. Disconnect fuel fill and vent lines from body.
3. Raise and support vehicle.
4. Support tank with a hydraulic jack.

Fuel Tank Assembly:

5. Remove 2 fuel tank strap nuts (8) and position straps (7) towards left side of vehicle.
6. Carefully lower tank a few inches and disconnect electrical connector at top of fuel pump 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 pump module is to be removed, thoroughly clean area at top of fuel pump around module.
11. If fuel tank is to be replaced, remove fuel pump module from tank. Refer to Fuel Pump Module Removal/Installation procedures.

Fuel Cooler Lines:

Fuel Line Pliers-9539:

12. If fuel cooler lines are to be removed, use special pliers #9539.

INSTALLATION

Fuel Tank Assembly:

Fuel Line Pliers-9539:

1. If fuel cooler lines are to be installed, use special pliers #9539.
2. If fuel tank is to be replaced, install fuel pump module into tank. Refer to Fuel Pump Module Removal/Installation procedures.
3. Position fuel tank to hydraulic jack.
4. Raise tank until positioned near body.
5. Connect fuel pump module electrical connector at top of tank.
6. Connect fuel supply and return lines.
7. Continue raising tank while guiding fill hose into body. Raise tank until positioned snug to body.

Fuel Cooler Lines:

8. Install and position both fuel tank support straps (7) to mounting bolts (1).
9. Install 2 fuel tank strap nuts (8). Refer to Torque Specifications.
10. Remove hydraulic jack.
11. Connect fill and vent hoses to body. Install ground wire to fill hose.
12. Lower vehicle.
13. Fill fuel tank with fuel.
14. Start engine and check for fuel leaks near top of module.