Fuel Tank Replacement (Long Wheelbase) (1)

Fuel Tank Replacement (Long Wheelbase) Single Use Fasteners and Components Fuel Sender Seal Special Tools CH–45722 Fuel Sender Lock Ring Wrench Equivalent regional tools: Special Tools

Warning

Refer to Diesel/Gasoline Vapors Warning.

Warning

Refer to Safety Glasses Warning. Removal Procedure

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

Fuel Tank Replacement (Long Wheelbase) (1) — figure 1

3. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Remove [4x]
4. Remove both rear stabilizer shaft clamp (2) from the frame and let the stabilizer shaft hang.

Fuel Tank Replacement (Long Wheelbase) (1) — figure 2

5. Fuel Feed Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
6. Fuel Return Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Tank Replacement (Long Wheelbase) (1) — figure 3

7. Fuel Tank Filler Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
8. Fuel Tank Filler Hose Clamp (2) » Loosen
9. Fuel Tank Filler Hose (3) » Remove

Fuel Tank Replacement (Long Wheelbase) (1) — figure 4

10. Place a suitable adjustable jack under the fuel tank.
11. Strap fuel tank to jack.
12. Fuel Tank Strap Bolt (1) » Remove [2x]
13. Fuel Tank Strap (2) » Remove [2x]

Fuel Tank Replacement (Long Wheelbase) (1) — figure 5

14. Lower the fuel tank, allowing clearance to access connections at the top of the tank.
15. Electrical Connector (1) » Disconnect
16. Fuel Feed Hose Clip (2) » Disengage
17. Wiring Harness Retainer (3) » Disengage [2x]
18. Retainer (4) » Unclip

Fuel Tank Replacement (Long Wheelbase) (1) — figure 6

19. Fuel Tank (1) » Remove
20. Remove the straps holding the fuel tank to the jack.
21. Remove the jack.

Fuel Tank Replacement (Long Wheelbase) (1) — figure 7

22. Fuel Tank Shield Retainer (1) » Remove [6x]
23. Fuel Tank Heat Shield (2) » Remove

Fuel Tank Replacement (Long Wheelbase) (1) — figure 8

24. Fuel Tank Filler Vent Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Disengage
25. Fuel Tank Filler Vent Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
26. Fuel Tank Filler Vent Hose (2) » Remove

Fuel Tank Replacement (Long Wheelbase) (1) — figure 9

27. Tape (1) » Remove
28. Evaporative Emission Hose (4) @ Fuel Tank Vent Valve Hose Clip (2) » Disengage [2x]
29. Evaporative Emission Hose (4) @ Retainer (3) » Disengage
30. Evaporative Emission Hose (4) » Disconnect — Plastic Collar Quick Connect Fitting Service
31. Evaporative Emission Hose (4) » Remove

Fuel Tank Replacement (Long Wheelbase) (1) — figure 10

32. Fuel Return Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Disengage [2x]
33. Fuel Return Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
34. Fuel Return Hose (2) » Remove

Fuel Tank Replacement (Long Wheelbase) (1) — figure 11

35. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Disengage [2x]
36. Fuel Feed Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
37. Fuel Feed Hose (2) » Remove

Fuel Tank Replacement (Long Wheelbase) (1) — figure 12

38. Fuel Sender Retainer (1) » Remove — CH–45722 Fuel Sender Lock Ring Wrench(2)

Fuel Tank Replacement (Long Wheelbase) (1) — figure 13

39. Fuel Tank Fuel Pump Module (1) » Remove

40. Fuel Sender Seal (2) » Remove and DISCARD Installation Procedure

41. Fuel Sender Seal (2) » Install NEW

42. Fuel Tank Fuel Pump Module (1) » Install

43. Fuel Sender Retainer (1) » Install — CH–45722 Fuel Sender Lock Ring Wrench(2)

44. Fuel Feed Hose (2) » Install

45. Fuel Feed Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

46. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Engage [2x]

47. Fuel Return Hose (2) » Install

48. Fuel Return Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

49. Fuel Return Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Engage [2x]

50. Evaporative Emission Hose (4) » Install

51. Evaporative Emission Hose (4) » Connect — Plastic Collar Quick Connect Fitting Service

52. Evaporative Emission Hose (4) @ Retainer (3) » Engage

53. Evaporative Emission Hose (4) @ Fuel Tank Vent Valve Hose Clip (2) » Engage [2x]

54. Tape (1) » Install

55. Fuel Tank Filler Vent Hose (2) » Install

56. Fuel Tank Filler Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

57. Fuel Tank Filler Vent Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Engage

58. Fuel Tank Heat Shield (2) » Install

59. Fuel Tank Shield Retainer (1) » Install [6x]

60. Place a suitable adjustable jack under the fuel tank.

61. Strap fuel tank to jack.

62. Raise the fuel tank  (1), allowing access to connections at the top of the tank.

63. Retainer (4) » Clip

64. Wiring Harness Retainer (3) » Engage [2x]

65. Fuel Feed Hose Clip (2) » Engage

66. Electrical Connector (1) » Connect

67. Raise the tank to the installed position.

68. Remove the straps holding the fuel tank to the jack.

69. Fuel Tank Strap (2) » Install [2x]

Caution

Refer to Fastener Caution.

30. Fuel Tank Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

31. Remove the jack.

32. Fuel Tank Filler Hose (3) » Install

33. Fuel Tank Filler Hose Clamp (2) » Tighten — Fastener Specifications

34. Fuel Tank Filler Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

35. Fuel Return Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

36. Fuel Feed Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

37. Raise rear stabilizer shaft into installed position.

38. Rear Stabilizer Shaft Clamp (2) » Install [2x]

39. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Install and tighten [4x] — Fastener Specifications

40. Lower the vehicle.

41. Refill the fuel tank.

42. Prime the fuel system and inspect for fuel leaks. Fuel System Priming