Tank, Fuel: Removal
WARNING:
The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.
- Remove the fuel fill cap.
- Raise and support vehicle. Refer to HOISTING, STANDARD PROCEDURE .
- Loosen the fuel fill hose clamp (2) at rear of tank (3) and disconnect fuel fill hose (1) from the fuel tank.NOTE:
There is a small flapper valve installed at the fuel tank filler opening.
- Using an approved diesel fuel draining station, position a drain hose into the fuel fill hose opening and drain the fuel tank.
- Disconnect quick-connect fittings (1) and (4) for fuel supply and return lines at front of tank.
- Disconnect the quick-connect fittings (6) and (8) for fuel vapor and vent lines at rear of tank. Refer to QUICK-CONNECT FITTINGS .
- Remove the front transfercase skid plate bolts (2) and the rear bolts (3) and remove the transfercase skid plate (4).
- Support the fuel tank with a hydraulic jack.NOTE:
The fuel tank skid plate and the fuel tank assembly are removed together. They share common fasteners.
- Remove the two fuel tank mounting bolts at the front of fuel tank.
- Remove the three fuel tank mounting bolts at right side of fuel tank.
- Remove the three fuel tank mounting bolts at left side of fuel tank.
- Partially lower tank to gain access to pump module wire harness connector (4). Disconnect the fuel pump module wire harness connector (4).
- Continue lowering the fuel tank for removal.
- Lift the fuel tank off the skid plate.
- If the fuel pump module is to be replaced, remove the fuel pump module from tank.