Lower Rack Assembly

FUEL TANK - LOWER RACK ASSEMBLY

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL

WARNING:
- The status (stuck open, normal operation, stuck closed or does not operate) of each fuel tank solenoid valve must identified prior to venting the fuel system. Venting of the fuel system without identifying solenoid status could result in an unexpected release of natural gas into the atmosphere, possibly resulting in injury or property damage.
- Eye protection is required when removing or installing fuel system components to avoid possible injury.

1. Carry out Pressure Relief-Fuel System.
2. Disconnect the battery ground cable.
3. Remove the LH rear wheel and tire assembly.
4. Remove the four pin-type retainers and remove the splash flap.







5. Remove the two upper stone shield retaining nuts.







6. Remove the lower stone shield retaining nuts and remove the stone shield.







7. Remove the lower tank rack assembly fuel tube connections.
1 Slowly loosen the upper tank rack to lower the tank rack fuel tube fitting at the top tank of the lower rack (tank No.5) to vent the residual system pressure. Disconnect the fitting once the residual pressure is released.
2 Disconnect the fuel supply tube fitting at the top of the "T" fitting on the top tank of the lower tank rack (tank No.5).







8. Disconnect the upper fuel tank rack assembly wiring harness connector.







9. Disconnect the lower fuel tank rack assembly wiring harness connector.







10. Remove the catalytic converter to tailpipe bolts.







11. Remove the tailpipe from the hanger and remove the tailpipe.







12. WARNING: The Rotunda Fuel Tank Removal Bracket Set 303-F010 (014-00470) or equivalent must be secured to the lower fuel rack assembly with the retaining pins or possible damage to the vehicle and possible personal injury can occur.

Attach the Rotunda Fuel Tank Removal Bracket Set "arms" and secure with the lower retaining pins.







13. WARNING: The Rotunda Fuel Tank Removal Bracket Set 303-F010 (014-00470) or equivalent must be secured to the lower fuel rack assembly with the safety chains or possible damage to the vehicle and possible personal injury can occur.

Line up and install the Powertrain Lift and the Rotunda Fuel Tank Removal Bracket Set with the lower tank rack guides. Install the safety chains on the bracket set.







14. Remove the six lower fuel tank rack assembly upper fasteners.
1 Remove the four bracket bolts.
2 Remove the two clamp-to-bracket nuts.







15. Remove the four lower tank rack assembly lower bolts, and carefully remove the lower fuel tank rack assembly.

INSTALLATION







1. WARNING: The Rotunda Fuel Tank Removal Bracket Set 303-F010 (014-00470) or equivalent must be secured to the lower fuel rack assembly with the safety chains or possible damage to the vehicle and possible personal injury can occur.

NOTE:
- Install new O-ring seals in the fuel tube connections. Natural gas approved O-ring seals are identified with a yellow stripe. Do not use unapproved O-ring seals.
- Lubricate the fuel tank solenoid O-ring seal with clean engine oil prior to installation to help seal and ease installation.
- When tightening the fuel tube, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the wrench being used. To correct the effective torque, a torque multiplication conversion must be used.

Position the lower fuel tank rack assembly to the body. Install the six lower fasteners to the lower rack assembly.
1 Install the two clamp-to-bracket nuts.
2 Install the four bracket bolts.







2. Install the four upper bolts of the lower rack assembly to the body.
3. Disconnect and remove the Rotunda Fuel Tank Removal Bracket Set.







4. Using new O-ring seals, connect the fuel tube fittings. Tighten to the specified torque using a torque wrench adapter.







5. Connect the lower fuel tank rack assembly wiring harness connector.







6. Connect the upper tank wiring harness connector.







7. Install the stone shield and the lower nuts.
8. Lower the vehicle.
9. Connect the battery ground cable.
10. Pressurize the fuel system.
1 Turn the jack screws counterclockwise until resistance is felt.
2 Turn the ignition switch to the RUN position.