Fuel Tank: Installation
- If fuel tank is to be replaced, install LDP, fuel filter and fuel pump module to tank. See FUEL PUMP and FUEL FILTER
for removal procedures.
- Position fuel tank to hydraulic jack.
- Raise tank while carefully guiding vent tubes/hoses through frame rail and crossmember. Before tank reaches body, connect electrical connector to Leak Detection Pump (LDP).
- Continue raising tank until positioned to body.
- Attach two fuel tank mounting straps and 4 mounting bolts. Tighten bolts to 61 N.m (45 ft. lbs.) torque.
- Connect 2 hoses to body retention clip at left/front of tank.
- Connect fuel filter fuel line to main fuel line (snaps together). After connecting, snap this line into body retention clip. Also connect LDP vacuum hose near this point.
Courtesy of DAIMLERCHRYSLER CORP.
- Install fuel fill hose and hose clamp to fuel tank fitting. Rotate hose until white painted index mark on hose is located between alignment notches on fuel tank fitting. See Figure. Tighten clamp to 3.4 N.m (30 in. lbs.) torque.
- Connect fresh air and recirculation lines to fuel fill tube.
- Connect 3/4" lines to Leak Detection Pump (LDP).
- Connect 3/4" flow management valve hose to EVAP canister.
- Snap remaining lines into body retention clip at front/center of fuel tank.
- If equipped, install fuel tank skid plate, trailer hitch and tow hooks.
- Lower vehicle.
- Attach (snap on) 2 fuel filter fuel lines to top of fuel pump module.
- Install electrical connector to top of fuel pump module.
- Connect negative battery cable to battery.
- Fill fuel tank with fuel.
- Start engine and check for fuel leaks near top of module.
- Apply silicone sealant to bottom of fuel pump module metal access plate.
- Install fuel pump module metal access plate and 4 nuts. Tighten nuts to 3 N.m (26 in. lbs.) torque.
- Position carpet and install 2 new cargo clamp rivets into each cargo hold down clamp.