Dodge Sprinter. Manual — part 248
Fig. 20 FUEL TANK ASSEMBLY
1 - Strap Bolts (2)
2 - Hose (not with all engines)
3 - Fuel Outlet Line
4 - Fuel Return Line
5 - Plug
6 - Fuel Tank
7 - Tank Straps (2)
8 - Nuts (2)
9 - Filler Tube
10 - Vent Hose
11 - Hose
12 - Clamps
13 - Cushioning Material
14 - Two-Way Valve
Fig. 21 FUEL COOLER LINES
1 - Expansion Tank
2 - Top of Tank
3 - Thermostat (Preheating Valve)
4 - Cooler Lines
5 - Connecting Hoses/Clamps
14 - 24
FUEL DELIVERY
VA
REMOVAL
(1) Drain diesel fuel from tank. Refer to Standard
Procedure — Draining Fuel Tank — Diesel.
(2) Disconnect fuel fill and vent lines from body.
(3) Raise and support vehicle.
(4) Support tank with a hydraulic jack.
(5) Remove 2 fuel tank strap nuts (8) (Fig. 23) and
position straps (7) towards left side of vehicle.
(6) Carefully lower tank a few inches and discon-
nect electrical connector at top of fuel pump module.
(7) Disconnect fuel supply line at tank.
(8) Disconnect fuel return line at tank.
(9) Continue to carefully lower tank for removal.
(10) If fuel pump module is to be removed, thor-
oughly clean area at top of fuel pump around module.
(11) If fuel tank is to be replaced, remove fuel
pump module from tank. Refer to Fuel Pump Module
Removal/Installation procedures.
(12) If fuel cooler lines (Fig. 24) are to be removed,
use special pliers #9539 (Fig. 25).
Fig. 22 TOP OF FUEL TANK
1 - Cooler Lines
2 - Top of Tank
3 - Expansion Tank
4 - Check Valves
5 - Check Valve
6 - Module Lock Ring
7 - Fuel Pump Module
VA
FUEL DELIVERY
14 - 25
INSTALLATION
(1) If fuel cooler lines (Fig. 27) are to be installed,
use special pliers #9539 (Fig. 28).
(2) If fuel tank is to be replaced, install fuel pump
module into tank. Refer to Fuel Pump Module
Removal/Installation procedures.
(3) Position fuel tank to hydraulic jack.
(4) Raise tank until positioned near body.
Fig. 23 FUEL TANK ASSEMBLY
1 - Strap Bolts (2)
2 - Hose (not with all engines)
3 - Fuel Outlet Line
4 - Fuel Return Line
5 - Plug
6 - Fuel Tank
7 - Tank Straps (2)
8 - Nuts (2)
9 - Filler Tube
10 - Vent Hose
11 - Hose
12 - Clamps
13 - Cushioning Material
14 - Two-Way Valve
Fig. 24 FUEL COOLER LINES
1 - Expansion Tank
2 - Top of Tank
3 - Thermostat (Preheating Valve)
4 - Cooler Lines
5 - Connecting Hoses/Clamps
Fig. 25 FUEL LINE PLIERS-9539
14 - 26
FUEL DELIVERY
VA
(5) Connect fuel pump module electrical connector
at top of tank.
(6) Connect fuel supply and return lines.
(7) Continue raising tank while guiding fill hose
into body. Raise tank until positioned snug to body.
(8) Install and position both fuel tank support
straps (7) (Fig. 26) to mounting bolts (1).
(9) Install 2 fuel tank strap nuts (8). Refer to
Torque Specifications.
(10) Remove hydraulic jack.
(11) Connect fill and vent hoses to body. Install
ground wire to fill hose.
(12) Lower vehicle.
(13) Fill fuel tank with fuel.
(14) Start engine and check for fuel leaks near top
of module.
VA
FUEL DELIVERY
14 - 27
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