TANK-FUEL
REMOVAL
GAS POWERED
WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.
1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure.
3. Remove fuel fill cap.
4. Raise and support vehicle.
5. Remove fuel fill hose clamp (2) at rear of tank (3).
6. Remove fuel fill hose (1) from fuel tank.
7. Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the opening.
8. Drain fuel tank using an approved gasoline fuel draining station.
The fuel tank skid plate and the fuel tank assembly are removed at the same. They share common fasteners.
9. Disconnect quick-connect fitting (2).
10. Disconnect quick-connect fitting (9).
11. Disconnect quick-connect fitting (10).
12. Remove hose clamp (3) and disconnect hose (4) at tank.
13. Support tank with a hydraulic jack.
14. Disconnect quick-connect fittings at front of tank.
15. Remove two tank mounting bolts at rear of fuel tank.
16. Remove three tank mounting bolts at right side of fuel tank.
17. Remove three tank mounting bolts at left side of fuel tank.
18. Partially lower tank to gain access to pump module electrical connector.
19. Disconnect electrical connector at fuel pump module.
20. Continue lowering tank for removal.
21. Lift fuel tank from skid plate.
22. If fuel tank is to be replaced, remove fuel pump module from tank.
DIESEL POWERED
1. Remove fuel fill cap.
2. Raise and support vehicle.
3. Remove fuel fill hose clamp (2) at rear of tank (3).
4. Remove fuel fill hose (1) from fuel tank.
5. Position a drain hose into the fuel fill hose opening. Note that a small flapper valve is installed into the opening.
6. Drain fuel tank using an approved diesel fuel draining station.
The fuel tank skid plate and the fuel tank assembly are removed at the same. They share common fasteners.
7. Locate quick-connect fitting (5).
8. Disconnect quick-connect fitting (5) by squeezing tabs (1).
9. Disconnect quick-connect fitting (2).
10. Support tank with a hydraulic jack.
11. Disconnect quick-connect fittings (1) and (4) for fuel supply and return lines at front of tank.
12. Remove two tank mounting bolts at rear of fuel tank.
13. Remove three tank mounting bolts at right side of fuel tank.
14. Remove three tank mounting bolts at left side of fuel tank.
15. Partially lower tank to gain access to pump module electrical connector (4).
16. Disconnect electrical connector (4) at fuel pump module.
17. Continue lowering tank for removal.
18. Lift fuel tank from skid plate.
19. If fuel tank is to be replaced, remove fuel pump module from tank.
INSTALLATION
GAS POWERED
The fuel tank skid plate and the fuel tank assembly are installed at the same. They share common fasteners.
1. If fuel pump module had been removed, install module to tank.
2. Position fuel tank into skid plate.
3. Support tank with a hydraulic jack.
4. Partially raise tank to allow connections at top of tank.
5. Connect electrical connector to fuel pump module.
6. Continue raising tank snugly to body.
7. Connect quick-connect fitting (2).
8. Connect quick-connect fitting (9).
9. Connect quick-connect fitting (10).
10. Install hose (4) to tank and install clamp (3).
11. Connect quick-connect fittings at front of tank.
12. Install two tank mounting bolts at rear of fuel tank.
13. Install three tank mounting bolts at right side of fuel tank.
14. Install three tank mounting bolts at left side of fuel tank.
DIESEL POWERED
1. If fuel pump module had been removed, install module to tank.
2. Position fuel tank into skid plate.
3. Support tank with a hydraulic jack.
4. Partially raise tank to gain access to pump module electrical connector (4).
5. Connect electrical connector (4) to fuel pump module.
6. Continue raising tank snugly to body.
7. Connect quick-connect fittings (1) and (4) for fuel supply and return lines at front of tank.
8. Install two tank mounting bolts at rear of fuel tank.
9. Install three tank mounting bolts at right side of fuel tank.
10. Install three tank mounting bolts at left side of fuel tank.
11. Connect quick-connect fitting (2).
12. Connect hose (1) and fuel fill hose clamp (2) at rear of tank (3).