Installing the Fuel Pickup Tube - Plastic Tank
DANGER: Diesel fuel vapors are potentially explosive. Use caution when working in or around the area of the diesel fuel tank.
DANGER: Before drilling drain all diesel fuel from the tank and use nitrogen or an inert gas to purge the diesel fuel vapors from the tank. Keep the diesel tank filled with inert gas while drilling.
DANGER: Use extreme caution when drilling into a diesel fuel tank. Sparks from an electric drill or drill bit could cause an explosion.
DANGER: Do not smoke while working near the diesel fuel tank. Diesel fuel vapors are potentially explosive.
1. Tape the paper template to the desired location on the diesel fuel tank and center punch the three holes.
NOTE: Use grease or special hole saws/drills that will minimize plastic chips from entering the fuel tank.
2. Drill two 9.5 mm (0.375 in.) diameter holes first. Drill 31.8 mm (1.25 in.) diameter hole next.
NOTE: Remove the template from the tank and remove any burrs from the hole.
Cut the end of the pickup tube so approximately 25.4 mm (1.00 in.) is above the bottom of the fuel tank.
Loosen the nut and slide all the parts to the top of the pickup tube assembly.
Hold the parts in position and slide the assembly into the hole at a slight angle until the bushing is inside the hole.
Tip the backup washer and slide it through the hole and position it onto the bushing. Thread the nut onto the bushing, position as needed to facilitate fuel line connections and tighten to 54.24 Nm (40 ft-lb.)
NOTE: Clean and flush the plastic fuel tank thoroughly to remove all plastic chips.