TANK - FUEL
REMOVAL - DIESEL
1. Drain fuel tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)
2. If equipped, remove fuel tank skid plate and tow hooks. Certain equipment packages will also require removal of the trailer hitch.
3. Support tank with a hydraulic jack.
4. Remove four fuel tank strap bolts (3) (2 at front of tank; 2 at rear of tank), and remove both tank support straps (4) .
5. Carefully lower tank a few inches.
6. Disconnect fuel tank module electrical connector (3) on top of fuel tank.
7. Disconnect fuel supply line (8) at front of fuel tank.
8. Disconnect fuel return line (7) at front of fuel tank.
9. Disconnect vent hose (5) .
10. Continue lowering tank while guiding remaining hoses and lines through plastic isolator sleeve on frame rail.
11. If fuel tank is to be replaced, remove fuel tank module from tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK MODULE - REMOVAL)
INSTALLATION - DIESEL
1. If fuel tank is to be replaced, install fuel tank module to tank. Refer to Fuel Tank Module Removal/Installation procedures.
2. Position fuel tank to hydraulic jack.
3. Raise tank while carefully guiding vent tubes/hoses through plastic isolator sleeve located on crossmember.
4. Continue raising tank until module electrical connector (7) can be connected. After connection has been made, continue to raise tank to body.
5. Connect fuel supply line (3) .
6. Connect fuel return line (6) .
7. Attach two fuel tank mounting straps (4) and four mounting bolts (3). Tighten bolts to 61 N·m (45 ft. lbs.) torque.
8. Install fuel fill hose and hose clamp to fuel tank fitting. Rotate hose until white painted index mark (3) on hose is located to alignment notch (4) on fuel tank fitting. Tighten clamp to 3.4 N·m (30 in. lbs.) torque.
9. If equipped, install fuel tank skid plate, trailer hitch and tow hooks. Refer to Tow Hooks, Trailer Hitch or Skid Plate in 23, Body for removal/installation procedures.
10. Lower vehicle.
11. Connect negative battery cable to battery.
12. Fill fuel tank with fuel.
13. Start engine and check for fuel leaks.