Upper Rack Assembly

FUEL TANK - UPPER 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. Remove the rear fuel tank rack assembly.







2. Remove the nylon retaining nuts and remove the flexible tube closeout shield.
3. Raise the vehicle.
4. Remove the LH rear wheel and tire assembly.
5. Remove the four pin-type retainers and remove the lower splash flap.







6. Slowly loosen the fuel tube nut fitting on the fuel tube to upper tank rack assembly to vent the system of residual pressure. Disconnect the fitting once the system is vented.







7. Disconnect the upper tank rack assembly wiring harness 8-pin connector and remove the connector from the bracket.







8. Remove the upper fuel tank rack assembly to body bolts, located above the rear axle area.
9. Lower the vehicle.







10. Remove the retaining nuts from the flexible tube and position the fuel tubes and wiring harness into the luggage compartment.







11. Remove the luggage compartment upper fuel tank rack assembly bolts.







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

Install the Rotunda Fuel Tank Removal Bracket Set into the upper fuel tank rack assembly guides and secure with the safety chains.







13. NOTE: Adjust the Rotunda Fuel Tank Removal Bracket Set as necessary to maintain clearance during removal of the upper tank rack.

Remove the upper fuel tank rack assembly using the Powertrain Lift and Rotunda Fuel Tank Removal Bracket Set or equivalent.


INSTALLATION







1. WARNING: The Rotunda Fuel Tank Removal Bracket Set 303-F010 (014-00470) or equivalent must be secured to the upper 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 line 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 upper fuel tank rack assembly into the vehicle using the Powertrain Lift with the Rotunda Fuel Tank Removal Bracket Set installed. Make sure the fuel lines and the upper tank rack wiring harness are positioned through the body opening that the flexible tube mounts to.

2. Remove the Powertrain Lift assembly from the upper fuel tank assembly.







3. Install the luggage compartment upper fuel tank rack assembly bolts.
4. Raise the vehicle.







5. Install the underbody upper fuel tank rack assembly retaining bolts located above the rear axle area.







6. Connect the upper fuel tank rack assembly wiring harness connector and install the connector onto the bracket.







7. Connect the upper tank rack assembly fuel tube fitting. Tighten to the specified torque using a torque wrench adaptor.
8. Install the LH rear wheel and tire assembly.
9. Lower the vehicle.







10. Install the flexible tube to body retaining nuts.







11. Install the flexible tube cover and tighten the nylon nuts securely.
12. Install the rear upper tank package.