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Home >> Dodge and Ram >> 2003 >> Durango Base, 5.9 Z, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 92 (Fuel Delivery) >> Fuel Tank >> Installation

Fuel Tank: Installation

WARNING: This page is about a different car, the 2004 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.

All 4-Door Models, or 2-Door Models Without ORVR System 

  1. If fuel pump module is being installed, Refer to FUEL PUMP MODULE REMOVAL INSTALLATION  .
  2. Install fill and vent hoses to tank fittings.
  3. Place and secure fuel tank to transmission jack.
  4. Raise tank up enough to connect fuel line, electrical connector and vapor hoses to top of fuel tank. Refer to QUICK-CONNECT FITTINGS  for fuel line procedures.
  5. Continue raising tank into position, and install mounting straps and nuts. Tighten nuts to 27--54 N.m (20-40 ft. lbs.) torque. Do not over tighten mounting strap nuts. 
  6. Remove transmission jack.
  7. If equipped, install fuel tank skid plate. .
  8. If equipped with a 2-piece driveshaft:
    1. Obtain new bolts and nuts to secure cross-member to frame. Use the same OEM bolts/nuts that are used to secure the upper fuel tank cross-member to the vehicle frame.
    2. Position crossmember to vehicle frame. Install bolts and tighten to 54 N.m, (40 ft. lbs.) torque.
    3. Position driveshaft and carrier bracket assembly to crossmember.
    4. Install bolts and tighten to 54 N.m (40 ft. lbs.) torque.
  9. Install fill and vent hoses to fill and vent tubes.
  10. Install splash shield in front of left/rear wheelhouse.
  11. Connect negative cable to battery.
  12. Refill fuel tank and install fill cap.
  13. Inspect all hoses and lines for leaks.

2-Door Models With ORVR System 

  1. If fuel pump module is being installed, refer to FUEL PUMP MODULE REMOVAL INSTALLATION  .
  2. Place and secure fuel tank to transmission jack.
  3. Raise tank up enough to connect fuel supply line, electrical connector and ORVR vapor line to top of fuel tank. Refer to QUICK-CONNECT FITTINGS  for fuel line procedures.
  4. Connect small vent line to fuel fill tube.
  5. Connect fuel fill hose to tank.
  6. Continue raising tank into position and install mounting straps and nuts. Tighten nuts to 27--54 N.m (20-40 ft. lbs.) torque. Do not over tighten mounting strap nuts. 
  7. Remove transmission jack.
  8. If equipped, install fuel tank skid plate. .
  9. If equipped with a 2-piece driveshaft:
    1. Obtain new bolts and nuts to secure cross-member to frame. Use the same OEM bolts/nuts that are used to secure the upper fuel tank cross-member to the vehicle frame.
    2. Position crossmember to vehicle frame. Install bolts and tighten to 54 N.m (40 ft. lbs.) torque.
    3. Position driveshaft and carrier bracket assembly to crossmember.
    4. Install bolts and tighten to 54 N.m (40 ft. lbs.) torque.
  10. Install splash shield in front of left/rear wheelhouse.
  11. Connect negative cable to battery.
  12. Refill fuel tank and install fill cap.
  13. Inspect all hoses and lines for leaks.
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