Fuel Tank Replacement Diesel

Caution: Refer to Battery Disconnect Caution in the Preface section.




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Disconnect the fuel fill hose (1) from the fuel tank.
5. Disconnect the fuel fill vent hose (2) from the fuel filler neck and cut the tie straps.
6. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
7. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to Metal Collar Quick Connect Fitting Service.
8. Disconnect the rear fuel feed pipe at the chassis fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service.
9. Disconnect the auxiliary heater fuel feed pipe.



10. With the aid of an assistant, support the fuel tank.
11. Remove the attaching bolts (4) from the fuel tank strap. Discard attaching bolts.
12. Remove the fuel tank straps (3).
13. Carefully lower the fuel tank.
14. Disconnect the fuel sender harness connector.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.



17. Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank. Refer to Fuel Sender Assembly Replacement.
18. On all models, remove the fuel fill hose from the fuel tank.
19. Remove the fuel tank from the fuel tank shield.

1. Install the fuel tank insulators (3).
2. Install the fuel tank into the fuel tank shield.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the fuel fill hose to the fuel tank.

Tighten
Tighten the fuel fill hose clamp to 2.75 N·m (24 lb in).

4. Install the (EVAP) hoses to the fuel tank and (EVAP) canister.
5. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement.



6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the fuel sender harness connector.
9. Raise the tank fully.
10. Install the fuel tank straps (3).

Important: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.

11. Install the new attaching bolts (4) to the fuel tank straps.

Tighten
Tighten the bolts to 52 N·m (38 lb ft).

12. Connect the auxiliary heater fuel feed pipe.
13. Connect the rear fuel feed pipe to the chassis fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service.
14. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Metal Collar Quick Connect Fitting Service.



15. Connect the fuel fill vent hose (2) to the filler neck.
16. Connect the fuel fill hose (1) to the fuel fill pipe.

Tighten
Tighten the fuel fill hose clamp to 2.75 N·m (24 lb in).

17. Lower the vehicle.
18. Refill the fuel tank.
19. Tighten the fuel filler cap.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection
21. Prime the fuel system. Refer to Fuel System Priming.