Service Procedure

1. Disconnect the negative battery cable from the battery after noting all electronic device settings.

2. Raise vehicle on hoist and support with safety stands.





3. Remove the steel shields (RPO ZM5) from around the fuel tank, if equipped (Figure 1).





4. Using a transmission jack, support the rear section of the fuel tank (use suitable padding between the fuel tank and jack, Figure 4).





5. Loosen the rear fuel tank strap (Figure 2, Item 3) in order to swing the side rail protector (Figure 5, Item 1) away from the bottom of the fuel tank.

6. Secure the side rail protector in the "swung out" position.





7. Use a "pre-sol" solution (DuPont 3919 or equivalent) to remove any dirt and grime from the fuel tank area where the seal and cover will be applied (Figure 3). The cleaning solution used must not leave any oily residue or film on the surface of the tank.

NOTE:
Prior to applying the fuel tank seal and cover in steps 8 and 9, be certain the surface is completely clean and dry.

NOTE:
The seal and cover (which is Butyl Mastic") must be applied above 60° F.

THE WORDS "SEAL" OR "COVER" ARE PRINTED ON THE APPROPRIATE PART. IT IS IMPORTANT THAT EACH PART IS INSTALLED IN THE PROPER SEQUENCE.

8. Take the fuel tank seal with the thin aluminum foil backing and peel approximately one inch of the protective paper away from the adhesive material.

9. Align the exposed adhesive side of the seal along the radius bend line at the fuel tank strap channel radius (Figure 4) and apply seal to fuel tank. Carefully remove remaining protective paper from the seal and apply the seal firmly to the bottom of the fuel tank. Smooth out the seal evenly onto the metal surface. Keep the side edges of the seal in parallel with fuel tank sides (make sure the seal's edges do not go beyond the radius of the other sides).

10. Take the cover with the thicker aluminum sheet backing and peel back approximately one inch of the protective paper from the adhesive material.

11. Align adhesive side of the cover along the same radius bend line on top of the seal (Figure 4) that was applied in step 9 above. Remove the remaining protective paper from the cover and apply the cover firmly over top of the seal, smoothing it out evenly.

12. Relocate the fuel tank side rail protector (be certain to center the rear protector tabs over the tank flange, Figure 2, Item 2). Reposition the fuel tank strap and insulator. Torque the fuel tank strap bolt to 18 Nm (13 lb.ft.) (Figure 2, Item 4).

13. Remove transmission jack from rear of fuel tank. Re-install fuel tank steel shield (RP0 ZM5) to vehicle if equipped (Figure 1, Item 2).

14. Lower vehicle from hoist and reconnect the negative battery cable. Reset all electronic devices as noted in step 1.

15. Install Campaign Identification Label.