Fuel Tank: Service and Repair

REMOVAL
Two different procedures may be used to drain fuel tank (lowering tank or using DRB scan tool). When equipped with these engines, the DRB scan tool cannot be used (no electric fuel pump).

The quickest draining procedure involves lowering the fuel tank.

If electric fuel pump is not operating, tank must be lowered for fuel draining. Refer to following procedures.
1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release procedure as described.
3. In this engine: Disconnect both negative battery cables at both batteries.
4. Raise vehicle on hoist.
5. Certain models are equipped with a separate grounding wire (strap) connecting the fuel fill tube assembly to the body. Disconnect wire by removing screw.
6. Open fuel fill door and remove screws mounting fuel filler tube assembly to body. Do not disconnect rubber fuel fill or vent hoses from tank at this time.
7. Place a transmission jack under center of fuel tank. Apply a slight amount of pressure to fuel tank with transmission jack.

Fig. 35 Fuel Tank Mounting - Typical:

8. Remove fuel tank mounting strap nuts from mounting strap studs (Fig. 35). If equipped, remove fuel tank shield bolts.
9. Lower fuel tank only enough to allow access to top of tank. The 2 tank fittings (where rubber fuel fill and vent hose connections are made) must be positioned above tank level. Rotate tank slightly to allow these fittings to be above tank level.
10. While working over left rear tire/wheel, disconnect rubber fuel vent hose at fuel tank (Fig. 35) (vent hose is the smallest of 2 hoses). Position fuel siphoning/drain hose into this fitting at tank. Drain fuel into an approved portable holding tank or a properly labeled diesel fuel safety container.
11. Disconnect rubber fuel fill hose at fuel tank (Fig. 35).

Fig. 39 Fuel Tank:

12. In this Engine:
a. While working over left rear tire/wheel, disconnect wiring harness connector from electrical connector at top of fuel tank module (Fig. 39).
b. Disconnect fuel supply and fuel return lines at the fuel tank module fittings (Fig. 39). Refer to Quick-Connect Fittings for procedures.

INSTALLATION
1. In this engine: If fuel tank module is being installed, refer to Fuel Tank Module Removal/installation.
2. Place fuel tank on top of transmission jack.
3. Install rubber fill and vent lines to tank. Tighten hose clamps to 2.3 Nm (20 in. lbs.) torque.
4. Raise tank into position while guiding fill and vent hoses to body. Raise tank only enough to allow access to top of tank.
5. In this Engines:
a. Connect electrical connector to fuel tank module.
b. Connect fuel supply and fuel return lines to fuel tank module fittings. Refer to Quick-Connect Fittings.
6. Connect two mounting straps and mounting strap nuts.
7. Tighten strap nuts to 41 Nm (30 ft. lbs.) torque. Do not over tighten retaining strap nuts.
8. Remove transmission jack.
9. Connect fuel filler tube assembly to body.
10. If equipped, connect grounding wire (strap) and screw.
11. Refill fuel tank and inspect all hoses and lines for leaks.
12. Connect negative battery cable(s) to battery(s).