Fuel Tank Replacement Rear

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 in General Information.



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 .

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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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 check for leaks.

Fuel Tank Replacement 15 Gallon Tank

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 in General Information.



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 .

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 check for leaks.

Fuel Tank Replacement Mid Mount

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



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 .

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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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 in Engine Electrical.
14. Prime the fuel system. Refer to Fuel Feed Pipe and Return Pipe Purging .
15. Start the engine and test for fuel leaks.