Primary - Cab/Chassis

REMOVAL PROCEDURE




1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the fuel tank shield (1).




4. Disconnect the fuel fill (2) and vent (1) pipes from the fuel tank.
5. Support the fuel tank, with the aid of an assistant.




6. Remove the fuel tank strap attaching bolts.
7. Remove the fuel tank straps (1).
8. Lower the fuel tank slightly.
9. Disconnect the fuel pipes from the fuel sender.
10. If equipped with an auxiliary fuel tank disconnect the rear chassis balance pipes.
11. Disconnect the fuel sender harness connector.
12. Remove the fuel tank.
13. Place the fuel tank in a suitable work area.
14. Cap the fuel pipes on the vehicle in order to prevent possible fuel system contamination.
15. Remove the fuel sender assembly from the fuel tank.

INSTALLATION PROCEDURE




1. Install the fuel sender assembly to the fuel tank.
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.
7. Fully raise the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel tank straps (1).

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




9. Connect the fuel fill (2) and vent (1) pipes to the fuel tank.

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




10. Install the fuel tank shield (1).
11. Lower the vehicle.
12. Refill the fuel tank.
13. Install the fuel filler cap.
14. Connect the negative battery cable
15. Prime the fuel system. Refer to Fuel Feed and Fuel Return Pipe Purge Procedure.
16. Start the engine and test for fuel leaks.