Fuel Tank Replacement Side Tank

Removal Procedure

1. Drain the fuel from the tank. Refer to Fuel Tank Draining .
2. If equipped with air tank , loosen the air tank clamp nuts and position the air tank to gain access to the fuel tank supports.
3. Support the fuel tank .



4. Remove the fuel tank support nuts .




Important: The fuel lines are not designed to uncoil and flex to provide added ease of removal. It may be necessary to remove the tape around the fuel line coil to gain more access.

5. Lower the fuel tank enough to disconnect the fuel lines and electrical connector.



6. Disconnect the fuel and EVAP lines. Refer to Metal Collar Quick Connect Fitting Service .
7. Disconnect the fuel sender assembly electrical connector.
8. Remove the fuel tank with the fuel tank supports from the frame rail.
9. Remove the fuel feed and return the line coils (1, 3) from the sending unit (2). Refer to Metal Collar Quick Connect Fitting Service .
10. Remove the fuel sender assembly if replacing or servicing the tank. Refer to Fuel Sender Assembly Replacement .
11. Remove the fuel tank steps. Refer to Step Replacement in Body Front End.
12. Remove the nuts, washers, and both fuel tank straps and supports from the fuel tank.
13. Remove the nut and the fuel sender assembly ground lead from the fuel tank. Note position of ground lead for installation.
14. Remove the fuel cap chain retainer and fuel cap if fuel tank is being replaced.
15. Purge the tank if the tank is being serviced. Refer to Fuel System Cleaning .

Installation Procedure

1. Install the fuel sender assembly if replacing or servicing the tank. Refer to Fuel Sender Assembly Replacement .

Notice: Refer to Fastener Notice in the Preface section.

2. Install the fuel tank ground lead.

Tighten
Tighten the nut to 9 N·m (7 lb ft).

3. Install the fuel feed and return the line coils (1, 3) from the sending unit (2). Refer to Metal Collar Quick Connect Fitting Service .
4. Install fuel tank chain to the fuel tank with retainer, if removed.
5. Install the fuel tank onto the fuel tank supports with the strap to the fuel tank supports.
6. Install the fuel tank strap nuts and the washers .

Tighten
Tighten the nuts to 175 N·m (129 lb ft).

7. Reconnect the fuel sender assembly electrical connector.



8. Install the fuel feed, fuel return , and EVAP lines to the fuel sender assembly . Refer to Metal Collar Quick Connect Fitting Service .
9. If fuel line tape was removed, tape fuel line coil.



10. Install the fuel tank supports to the frame with 2 anchor plates and 6 nuts.

Tighten
Tighten nuts to 175 N·m (129 lb ft).

11. Slide the fuel tank into position and support the fuel tank.
12. Install the fuel tank steps. Refer to Step Replacement in Body Front End.
13. Refill the fuel tank.
14. Inspect for leaks.

Fuel Tank Replacement Rear

Removal Procedure

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. Raise the vehicle on a suitable hoist. Refer to Lifting and Jacking the Vehicle .



3. If equipped with a fuel tank shield, support the fuel tank shield.
4. If equipped with a fuel tank shield, remove the 16 bolts and the fuel tank shield from the frame.

Important: Clean all the fuel pipe and hose connections as well as the surrounding areas before disconnecting the fuel pipes and hoses.

5. Disconnect the vent hose at the fuel tank.
6. Disconnect the filler tube at the fuel tank.



7. Support the fuel tank.
8. With the aid of an assistant, remove the fuel tank strap attaching bolts and the fuel tank strap bolts.
9. Lower the fuel tank enough to disconnect the fuel sender electrical connector and the retaining clips.
10. Remove the nut and ground strap from the fuel sender assembly.
11. Disconnect the hoses from the fuel sender assembly.
12. Remove the fuel tank from the vehicle and place the tank in a suitable work area.
13. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

1. Install the fuel sender assembly with new O-rings on the fuel pipes. Refer to Fuel Sender Assembly Replacement .



2. Position and support the fuel tank.
3. Position the fuel tank straps and connect the fuel feed and return hoses to the fuel sender fittings.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the ground strap to the fuel sender assembly with nut.

Tighten
Tighten the nut to 9 N·m (80 lb in).

5. Connect the electrical connector to the fuel sender assembly.
6. Install the retaining clips.
7. Install the fuel filler vent hose to the vent pipe.
8. Install the fuel filler neck connecting tube to the fuel tank.
9. Install the fuel tank strap bolts.

Tighten
Tighten the fuel tank strap bolts to 35 N·m (26 lb ft).

10. Install the fuel tank attaching bolts.

Tighten
Tighten the fuel tank attaching bolts to 85 N·m (63 lb ft).




11. If equipped with a fuel tank shield, install the fuel tank shield to the frame with 16 bolts.

Tighten
Tighten the fuel tank shield bolts to 175 N·m (129 lb ft).

12. Start the engine and inspect for leaks.

Fuel Tank Replacement 15 Gallon Tank

Removal Procedure

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. If required, raise the vehicle on a suitable hoist. Refer to Lifting and Jacking the Vehicle .



3. Support the fuel tank shield.
4. Remove the 4 nuts, 2 bolts and fuel tank shield from the frame.

Important: Clean all the fuel pipe and hose connections as well as the surrounding areas before disconnecting the fuel pipes and hoses.

5. Disconnect the vent hose at the fuel tank.
6. Disconnect the filler tube at the fuel tank.



7. Support the fuel tank.
8. With the aid of an assistant, remove the fuel tank strap attaching bolts and the fuel tank straps.
9. Lower the fuel tank enough to disconnect the fuel sender electrical connector and the retaining clips.
10. Disconnect the hoses from the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
11. Remove the fuel tank from the vehicle and place the tank in a suitable work area.
12. If required, remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

1. Install the fuel sender assembly with new O-rings on the fuel pipes. Refer to Fuel Sender Assembly Replacement .



2. Position and support the fuel tank.
3. Position the fuel tank straps and connect the fuel feed and return hoses to the fuel sender fittings.
4. Connect the electrical connector to the fuel sender assembly.
5. Install the retaining clips.
6. Install the fuel filler vent hose to the vent pipe.
7. Install the fuel filler neck connecting tube to the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.




8. Install the fuel tank strap bolts.

Tighten
Tighten the fuel tank strap bolts to 40 N·m (30 lb ft).

9. Install the fuel tank shield with 4 nuts and 2 bolts.

Tighten
Tighten the fuel tank shield nuts and bolts to 85 N·m (63 lb ft).

10. If required, lower the vehicle.
11. Start the engine and inspect for leaks.

Fuel Tank Replacement Mid Mount

Removal Procedure

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .



3. Disconnect the fuel fill and vent pipes from the fuel tank.
4. Support the fuel tank, with the aid of an assistant.




Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

5. Remove the fuel tank strap attaching bolts.
6. Remove the fuel tank straps.
7. Lower the fuel tank slightly.
8. Disconnect the fuel pipes from the fuel sender. Refer to Metal Collar Quick Connect Fitting Service .
9. If equipped with an auxiliary fuel tank, disconnect the rear chassis balance pipes.
10. Disconnect the fuel sender harness connector.
11. Remove the fuel tank.
12. Place the fuel tank in a suitable work area.
13. Cap the fuel pipes on the vehicle in order to prevent possible fuel system contamination.
14. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
2. Remove the caps from the fuel pipes.
3. Support and partially raise the fuel tank, with the aid of an assistant.
4. Connect the fuel sender harness connector.
5. If equipped with an auxiliary fuel tank connect the rear chassis balance pipes.
6. Connect the fuel pipes to the fuel sending unit. Refer to Metal Collar Quick Connect Fitting Service .
7. Fully raise the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

8. Install the fuel tank straps.

Tighten
Tighten the fuel tank strap attaching bolts to 40 N·m (30 lb ft).




9. Connect the fuel fill and vent pipes to the fuel tank.

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

10. Lower the vehicle.
11. Refill the fuel tank.
12. Install the fuel filler cap.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
14. Start the engine and test for fuel leaks.