Front - Cab/Chassis

FUEL TANK REPLACEMENT (CAB/CHASSIS - FRONT)

REMOVAL PROCEDURE




1. Disconnect the fuel feed and pressure balance rear lines.




2. Loosen the fuel fill and vent hose clamps (1, 2) at the fuel tank.
3. Remove the fuel fill pipe and vent hose from the tank.
4. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.




5. Disconnect the sending unit electrical connectors (1).




6. Disconnect the fuel feed and return lines from the fuel tank.
7. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




8. If necessary, remove the fuel tank shield bolts.
9. If necessary, remove the fuel tank shield.
10. Place a suitable adjustable jack under the fuel tank.




11. Remove the fuel tank strap bolts.

NOTE: Refer to Fuel Tank Strap Fastener Notice in Service Precautions.

12. Remove the fuel tank straps.
13. Lower the fuel tank.
14. With the aid of an assistant, place the fuel tank in a suitable work area.
15. Cap the fuel lines on the vehicle in order to prevent possible fuel system contamination.
16. If replacing the fuel tank, remove the sending unit.

INSTALLATION PROCEDURE




1. If the fuel tank was replaced, install the sending unit.
2. Remove the caps from the fuel lines.
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank.
5. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N.m (30 lb ft).

7. Remove the jack from under the fuel tank.




8. If necessary, install the fuel tank shield.
9. If necessary, install the fuel tank shield bolts.

Tighten
Tighten the bolts to 18 N.m (13 lb ft).

10. Lower the vehicle.




11. Connect the fuel feed and return lines at the fuel tank.




12. Connect the sending unit electrical connectors (1).




13. Install the fuel fill pipe and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps (1, 2) at the fuel tank.

Tighten
Tighten the clamps to 2.5 N.m (22 lb in).




15. Connect the fuel feed and pressure balance rear lines.
16. Fill the fuel tank.
17. Install the fuel fill cap.
18. Connect the negative battery cable.
19. Prime the fuel system. Refer to Fuel System Priming.
20. Start the engine. If the engine stalls, repeat the above step.
21. Once the engine starts, inspect for fuel leaks.