Fuel Tank Removal and Installation

Fuel Tank - REMOVAL

1. Loosen clamp and disconnect rubber fuel fill hose at tank.
2. Support tank with a hydraulic jack.

Fig.22 Fuel Tank Mounting:

3. Remove 2 fuel tank strap nuts (Fig. 22) and remove both tank support straps.

Fig.21 Fuel Tank Module - Diesel:

4. Carefully lower tank a few inches and disconnect fuel pump module electrical connector (Fig. 21) at top of tank. To disconnect electrical connector:Push upward on red colored tab to unlock. Push on black colored tab while removing connector.
5. Disconnect fuel supply and return lines at fuel tank module (Fig. 21). Refer to Quick-Connect Fittings for procedures.
6. Continue to lower tank for removal.
7. 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 to tank module.
6. Continue raising tank until positioned snug to body
7. Install and position both tank support straps. Install 2 fuel tank strap nuts and tighten. Tighten rear strap nut first. Refer to Torque Specifications.
8. Remove hydraulic jack.
9. Connect rubber fill hose to fuel fill tube and tighten clamp.
10. Install tire I wheel (if necessary).
11. Lower vehicle.
12. Fill fuel tank with fuel.
13. Start engine and check for fuel leaks near top of module.