Fuel Tank Replacement (2500 LWB - 98.4L (26 gal) Tank-Front)

Fuel Tank Replacement (2500 LWB - 98.4L (26 gal) Tank-Front)

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

Removal Procedure

Important: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Drain the fuel tank. Refer to Fuel Tank Draining (Single Tank) Fuel Tank Draining (Dual Tanks - Front) Fuel Tank Draining (Dual Tanks - Rear).
3. Disconnect the fill pipe evaporative emission (EVAP) line quick connect fitting (2) from the fuel tank vent valve.




4. Disconnect the EVAP line quick connect fitting (1) from the fuel tank vent valve.




5. Disconnect the chassis fuel feed and EVAP line quick connect fittings from the fuel tank line quick connect fittings.




6. Open the clip on the side of the fuel tank retaining the intermediate lines.
7. Disconnect the fuel and EVAP intermediate line quick connect fittings from the front tank lines.
8. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.




9. Using an adjustable jack, support the fuel tank.

Notice: Refer to Damage to Fuel Tank Straps Notice.

10. Remove the fuel tank strap bolts.
11. Remove the fuel tank straps.

Important: When lowering the fuel tank, ensure that the EVAP line does not get caught on anything.

12. With the aid of an assistant, carefully lower the fuel tank until the electrical connectors can be accessed.




13. Disengage the connector position assurance (CPA) retainer.
14. Disconnect the chassis harness electrical connector (1) from the fuel tank module.
15. Completely lower the fuel tank.
16. Place the fuel tank in a suitable work area.
17. If replacing the fuel tank proceed to the next step, otherwise proceed to step 14 in the installation procedure.




18. Remove the fuel tank shield retainers (1) and shield (2).




19. Remove the EVAP line from the fuel tank clip (1).
20. Open the fuel tank clips (2-7) and remove the fuel/EVAP lines from the clips.
21. Disconnect the fuel/EVAP line quick connect fittings from the fuel tank module.




22. Remove the fuel/EVAP lines from the fuel tank.




23. Using the J 45722 remove the lock ring.




24. Carefully lift the module from the fuel tank, enough to access the quick connect fitting (1) under the module cover. Disconnect the quick connect fitting.
25. Remove the fuel tank module.
26. Remove and discard the fuel tank module seal.






Important:
* Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.

* Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

* Check the lock ring for flatness.

Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.

27. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
28. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

Installation Procedure




1. If the fuel tank was replaced perform the following steps, otherwise proceed to step 14.
2. Install the NEW fuel tank module seal onto the fuel tank.
3. Pull the vent line in the fuel tank up as far as possible for ease of installation.
4. Position the fuel tank module part way into the fuel tank.
5. Connect the quick connect fitting (1) to the module cover.
6. Install the fuel tank module into the fuel tank.
7. Place the lock ring into position.




8. Rotate the lock ring counterclockwise using the J 45722




9. Install the EVAP lines to the fuel tank.




10. Connect the EVAP line quick connect fittings at the fuel tank module.
11. Install the EVAP lines to the fuel tank clips (2-7) and close the clips.
12. Install the EVAP line to the fuel tank clip (1).




13. Install the fuel tank shield (2) and retainers (1).




14. Place the fuel tank onto a suitable jack.
15. With the aid of an assistant, partially raise the fuel tank.
16. Connect the chassis harness electrical connector (1) to the fuel tank module.
17. Engage the CPA retainer.






Important: When installing the fuel tank, ensure that the EVAP line is correctly routed over the frame.

18. With the aid of an assistant, completely raise the fuel tank.
19. Install the fuel tank straps.

Notice: Refer to Fastener Notice.

20. Install the fuel tank strap bolts.

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

21. Remove the adjustable jack from under the fuel tank.




22. Remove the caps from the fuel and EVAP lines.
23. Connect the fuel and EVAP intermediate lines to the front tank.
24. Install the lines to the clip on the side of the fuel tank and close the clip.




25. Connect the chassis fuel feed and EVAP line quick connect fittings to the fuel tank line quick connect fittings.




26. Connect the EVAP line quick connect fitting (1) to the fuel tank vent valve.




27. Connect the fill pipe EVAP line quick connect fitting (2) to the fuel tank vent valve.
28. Install the fuel fill hose to the fuel tank.
29. Tighten the fuel fill hose clamp at the fuel tank.

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

30. Lower the vehicle.
31. Refill the fuel tank.
32. Install the fuel fill cap.
33. Connect the negative battery cable.
34. Use the following procedure in order to inspect for leaks:

1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.

35. Install the intake manifold sight shield.