4

SI B16 03 17 Procedure

June 2018
8. Install the cap (1) onto the filler neck.
Install the third ground clip to the brass lug
found on the side of the cap (2).
Begin extracting fuel.
When the available fuel is siphoned from the
fuel tank, remove the siphon tube and reinstall
the fuel filler cap.
Proceed to the next step.

9. Remove the fuel tank as per Repair Instruction
16 11 030 “Removing and installing fuel tank
(M56).
The fuel tank MUST be removed from the
vehicle with it level to the ground as shown in
the illustration. Do not turn or twist the tank in
any other direction when removing it.
Use the special tools or similar tools to keep
the fuel tank level with the ground.
Use a suitable jack with the basic carrier for
special tool 00 2 040.
Assemble the basic carrier with special tools
16 1 180.
Keeping the tank level with the ground will
allow the fuel to be siphoned more efficiently
for shipping.
Do not drill any holes in the fuel tank or cut
the fuel filler neck to drain the fuel. The fuel
tank assembly must be returned 100 percent
intact without any damage.

5

SI B16 03 17 Procedure

June 2018
10. Using two people, remove the fuel tank from
the basic carrier or suitable lifting device.
Place the fuel tank flat on the ground as shown
in the illustration
Always keep the fuel tank level with the ground
when moving it.
Do not dent or scratch the fuel tank when
performing these instructions.
Place the fuel tank on a smooth surface so
that the bottom of the fuel tank is not
damaged.
Place a large piece of scrap cardboard
under the fuel tank to avoid damage when
performing these instructions.

11. Tank overview.
Left (1)
Right (2)
Front (3)
Back (4)
Filler Neck (5)
Arrow = Direction of vehicle travel

Supplemental Draining After Removal of Tank:
12. The residual fuel will need to be siphoned from
the fuel tank again after it is removed.
Please perform the supplemental draining
process in a well-ventilated area.
Adjust the siphon hose plastic sliding stop and
mark the hose with an ink marker at 65 inches
(165Cm) from the stainless steel tip of the
siphon hose.

6

SI B16 03 17 Procedure

June 2018

13. Insert the siphon hose sleeve (1) into filler neck
(2).

14. Connect one of the three grounds clips (1) to
the brass connection where the siphon hose (2)
meets the gas caddy hose (3).

15. Connect one of the two remaining ground clips
(1) to the gas caddy pump housing.

7

SI B16 03 17 Procedure

June 2018
16. Insert the siphon hose.
Lubricate the lower 30 inches of the siphon
hose with WD-40 or similar before inserting.
When the hose stops continue to apply
pressure while turning hose 90 degrees
clockwise and counterclockwise in each
direction. See arrows.
The siphon hose tip will continue traveling
through the lower filler neck flap and into the
fuel tank.

17. The filler neck diameter is very narrow and will
cause the hose to spring backwards when
inserted.
Push the hose in about 2-3 inches too far and
pull back out gently until the previously marked
area on the siphon hose lines up with the edge
of the siphon hose sleeve (1).
The siphon hose must be inserted to the
specified length to achieve proper siphoning
results.

18. Adjust the siphon hose sliding stop (1) so that it
contacts the siphon hose sleeve.

8

SI B16 03 17 Procedure

June 2018
19. Install the cap (1) onto the filler neck (2).

20. Install the third ground clip (1) onto the brass
lug found on the side of the cap (2).

21. The fuel tank is lying flat on the floor with the
siphon tube inserted and ready to extract fuel.
Activate Siphon – Extract Fuel

9

SI B16 03 17 Procedure

June 2018

22. Lift the fuel tank from the left side and hold it
upright with the filler neck on the ground
position for 30 seconds while activating the
siphon pump to extract all fuel accumulated at
the bottom of the tank. See arrow.
After 30 seconds, lower the fuel tank to the
floor.
Activate Siphon – Extract Fuel

23. Slightly tilt the fuel tank so that all of the fuel
moves to the portion of the fuel tank that is
closest to the filler neck. Do this by lifting the
left side of the fuel tank to 70 degrees.
Lean the fuel tank against the wall or a work
bench as shown in the illustration.
Use an angle finder to precisely measure the
angle of the fuel tank.
Activate Siphon – Extract Fuel
Siphon as much fuel from the fuel tank as
possible, by rotating the tank through various
angles while siphon pump is active.
If using a powered fuel extraction pump, let the
pump run for approximately 30 seconds after
the pump stops siphoning the fuel and before
lowering the fuel tank again.
If using a manual fuel extraction pump,
continue cranking for approximately 30
seconds after the pump stops siphoning the
fuel and before lowering the fuel tank again.

10

SI B16 03 17 Procedure

June 2018
24. Lower the fuel tank and keep it level with the
floor.
Remove the siphon hose.

25. The tank will need to be stored for the TSE to
conduct a final inspection and a weight check.
An additional draining process may be needed
to ensure that the maximum amount of fuel has
been extracted.
The final weight of the tank without filler cap
and plugs must be 40 pounds or less, before it
can be shipped.
Please proceed with part 2 to prepare the tank
for temporary storage and onsite inspection by
TSE.

11

SI B16 03 17 Procedure

June 2018

Part 2: Preparing and Packing The Fuel Tank to Hold for
Onsite Review by TSE.
1. The fuel tank return preparation kit includes
various plugs, caps, wire ties and bags for
securing and packaging the fuel tank

2. For the initial draining procedure, and to store
the tank in the original box, use only the
following items:
1 - Extra Large 3 Mil Clear Bag (48x35x72)
1 - Liquid Absorbent Pad
1 - Mini Re-closable Bag
1 - Cable Tie
1 - Red Silicone Stoppers

12

SI B16 03 17 Procedure

June 2018
3. The additional un-used items from the kit
should be retained in the original bag for the kit
and placed into the box with the tank.
1 - Adhesive Envelop for Shipping Documents
1 - UN3336 Label
2 - Mini Re-closable Bags
1 - DOT Label
3 - Cable Ties
1 - M24 Hex Socket Pipe Plug
1 - Red Silicone Stopper
1 - Bag containing kit contents

4. Reuse the original fuel filler cap to return the
defective fuel tank.

13

SI B16 03 17 Procedure

June 2018
5. Install one of the red tapered plugs (Red
Silicone Stopper) included in the kit onto the
short hose (fuel supply line).

6. The new fuel tank will be equipped with a black
protective cap on the short hose (fuel supply
line).
Reuse the black cap and install it on the used
fuel tanks short hose, placing it over the red
tapered plug.

7. Using one of the small bags and a cable tie
included in the kit, wrap and tie the bag so it is
covering the entire length of the black
protective cap.

14

SI B16 03 17 Procedure

June 2018
8. The new fuel tank will be equipped with a black
protective cap on the long hose that connects
to the fuel filler neck.
Reuse the black cap and install it on the used
fuel tank’s long line.

9. Remove the protective cap from the filler neck
on the new fuel tank and install it onto the used
fuel tank, in the same location.

10. Remove the electrical connector protective cap
from the new fuel tank and install it onto the
used fuel tank electrical connector.

15

SI B16 03 17 Procedure

June 2018
11. Prepare the large shipping bag included in the
kit.

12. Place the used fuel tank inside the shipping
bag.
Place the white absorbent pad included in the
kit under the center of the fuel tank.

13. Leave the shipping bag open do not seal the
bag at this time.
Place the used fuel tank, diagonally, into the
corrugated box that the new tank was received
in.
Please do not use the bag to lower the tank
into the box, as it will tear.
Ensure that the filler neck is not bent
sharply. Potential damage to the filler neck
must be avoided in order to remanufacture the
tank.
Keep the unused labels, bags and ties in the
bag and place it into the box. They will be
needed once the tank is approved for
transport.
14. DCSnet Part Tag
16

SI B16 03 17 Procedure

June 2018
a. DO NOT SHIP/RETURN THIS OR ANY
USED TANK TO THE WPRC OR RDC.
Create/submit an IDS ticket to the WPRC
indicating the VIN and that a tank is
available for pickup.
•

Inform your TSE.

•

Further instructions for next steps will be
provided once the TSE has confirmed
the weight and inspected the tank.

b. Print and attach the corresponding DCSnet
Part Return Tag or Core Return Tag to the
fuel tank.
c. Pre-tag the corrugated box to identify this
item and secure it in your center’s parts
retention area.
All tanks should be retained whether in
warranty or out of warranty.
Any damage attributed to removal, where
the tank cannot be remanufactured, will be
subject to a claim or core charge
adjustment.

17