8 N.m
(20 in-lb)

Make sure the O-ring
is properly seated.

4. Coil the pigtail harness on the end of the
solenoid valve, then position the 2.5-inch
socket over it, making sure the pigtail fits
inside the socket.

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2. Install the nitrogen gas regulator supplied in
the kit to the gas cylinder, and make sure the
regulator key is unscrewed most of the way
without removing it.
NOTE: Always wear safety glasses when
working with pressure.

4. Open the main nitrogen cylinder valve number 1 as
follows:
• Turn the regulator key number 2 clockwise
to set the regulator to 400 PSI.
• When the hissing stops, the tank is
fully pressurized.
Open the main

NITROGEN GAS
REGULATOR

GAS
CYLINDER

REGULATOR KEY

3. Connect the high pressure hose from the kit
to the solenoid valve adapter and the gas
regulator. Make sure the nitrogen tank is
safely supported.
HIGH
PRESSURE
HOSE

nitrogen cylinder
valve.

1

2
Turn the regulator key until
the gauge reads 400 psi.

SOLENOID
VALVE
ADAPTER

NITROGEN TANK

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5. To check the solenoid valve O-ring for leaks,
apply Snoop Liquid Leak Detector at the base
of the solenoid valve. Check for bubbles
around the O-ring seal. Use only Snoop Liquid
Leak Detector because the nitrogen will not be
detected by an electronic detector.
• If there are no bubbles, go to step 7.
• If there are bubbles, go to step 6.

SNOOP LIQUID
LEAK DETECTOR

8. Install new O-rings on the three connectors.
First apply tape over the connector threads to
keep from scratching the O-rings while
installing them. After installation, remove the
tape, and lubricate the O-rings with PAG oil.
> Fuel Line Connector O-Ring (1/4 in. Port Side) (2)
> Fuel Line Connector O-Ring (3/8 in. Port
Side)

NEW O-RING

6. Call Tech Line for a procedure to release the
nitrogen from the fuel tank without damaging
it, then remove the solenoid valve. Check the
sealing surfaces for debris, clean as needed,
then do the following:
• Check the sealing surface of the valve. If
it is damaged, replace the valve and the
O-ring.
• Replace the O-ring with a new one.
• Install the solenoid valve, then repeat
steps 3 thru 5 to check for leaks.
7. If no leaks are found, close the nitrogen
cylinder valve, loosen the regulator key, and
slowly loosen the hose fitting at the fuel tank
adapter to bleed off pressure in the hose.
Only a small amount of gas should be
released when breaking the seal on the hose.
• If gas continues to vent, the solenoid check
valve is defective. Remove and replace the
solenoid valve and O-ring with a new one,
then repeat the leak check procedure.
• If nitrogen pressure does not leak
continuously when the line is cracked
open, remove the high pressure hose and
the adapter fitting from the solenoid valve.
NOTE: The nitrogen will remain in the tank.

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9. Install the three different connectors fingertight in the correct port.
NOTE: Each connector is different. Make
sure the correct connector is installed in the
proper port.
• The large fuel line connector is installed in
the large port.
• The pressure relief device is the same
diameter as the small fuel line connector,
but it is shorter. Make sure this connector
is installed in the port shown.
• The small fuel line connector is the same
diameter but longer than the pressure
relief device. Make sure this connector is
installed in the port shown.

10. Install the three main fuel line connectors
by making sure the tank is on its side, then,
using a 5/8 inch crowfoot wrench on the
smaller fittings and a deep socket on the large
fitting, torque the fittings to these specifications:
• Small connectors: 20 N•m (15 lb-ft)
• Large connector: 34 N•m (25 lb-ft)
NOTE: Do not place O-rings on the outside of
the connectors yet.
FUEL LINE
CONNECTOR

34 N.m (25 lb-ft)
PRESSURE RELIEF
DEVICE (PRD)

20 N.m (15 lb-ft)

FUEL LINE
CONNECTOR

PRESSURE
RELIEF
DEVICE (PRD)

FUEL LINE
CONNECTOR

FUEL LINE
CONNECTOR

20 N.m (15 lb-ft)

Shorter Longer

PRESSURE
RELIEF
DEVICE (PRD)

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FUEL LINE CONNECTORS

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Align and Connect the Fuel Lines
NOTE: Alignment of the fuel lines is important.
When installing a new fuel tank solenoid valve,
the alignment will change.
1. Place a piece of masking tape on both tank
bands near the spring retaining bolt
assemblies.
NOTE: Installation of the new solenoid valve
will change the alignment of the lines to the
tank valve. Alignment of the lines to the valve
is a critical step.

4. With the help of another assistant, carefully
rotate the tank assembly as needed until the
three fuel line flanges align flush with the line
connector position (hold the nut back to see).
NOTE: The fuel tank may be stuck to the
rubber cushions on the tension bands. Rock or
lift the tank slightly to free it if needed.
Fuel line flanges
misaligned.
Rotate the tank.

SPRING RETAINING
BOLT ASSEMBLY
VERNIER CALIPERS

TANK BAND
SPRING
TAPE

Record the spring
measurements here.

2. Measure both of the tank band spring lengths
using a Vernier caliper. Record the
measurement on the piece of tape that was
placed on the tank band. You will need this
later for assembly.
3. Loosen and remove the tank band spring
retaining bolts.

Rotate the tank
while watching fuel
line flange
alignment.

Fuel line
flanges are
aligned.

TANK BAND SPRING
RETAINING BOLT

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5. Lubricate the three O-rings with PAG oil, then
install them on the connectors.
> Fuel Line Connector O-Ring (1/4 in.)(2)
> Fuel Line Connector O-Ring (3/8 in.)
6. While holding the fuel line tight against the
fitting, first, hand-tighten the nut, then torque
the line nuts to make sure the O-ring does not
get misaligned and damaged. Torque to these
specifications:
• Small connectors: 27 N•m (20 lb-ft)

9. Make sure the vertical lines on the tank align
with the tank bands.
NOTE: After the new solenoid valve is
installed, if the marks are rotated to the rear,
align them with the tank bands in the rear,
then make new marks on the side of the tank
that will face the trunk opening.
VERTICAL LINES
TANK

• Large connector: 47 N•m (35 lb-ft)
7. Use a backup wrench on the connector
fitting when tightening.
LARGE CONNECTOR
LINE NUT

47 N.m (35 lb-ft)

TANK BANDS

10. Install and torque the spring retaining bolt lock
nuts to 38 N•m (28 lb-ft).
LOCK NUT

38 N.m
(28 lb-ft)
SMALL CONNECTOR
LINE NUTS

27 N.m (20 lb-ft)

8. Make sure the tank does not shift when
installing the tank band spring retaining bolt
assemblies. Tighten them until the spring
length is the same as previously recorded.
NOTE: Make sure the new alignment is
correct before tightening the tank bands.
PREVIOUSLY RECORDED
SPRING LENGTH

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11. Remove the old horizontal paint markings
from the tank only, (not from the tank bands)
using contact brake cleaner.
NOTE: Use the cleaner sparingly to
avoid damaging the fuel tank paint.
HORIZONTAL LINES

Note how they shifted when the
tank bands were retightened.

Assemble the Seal Boot and Backing Plate
1. Using the spanner from the kit, loosen the seal
boot backing plate collar, and rotate the
backing plate to its original position.
NOTE: Use the solenoid valve wire harness
clip as a guide to positioning the backing
plate. Rotate the plate until the harness clip
lines up with the tab.
BACKING PLATE TAB

(Rotate to line up with
the subharness clip.)
SEAL BOOT
BACKING PLATE
SEAL BOOT BACKING
PLATE COLLAR

77 N.m (57 lb-ft)

Remove the horizontal
marks from the tank only.

12. Mark the fuel tank horizontal lines using the
yellow paint marker supplied in the kit. Trace
over the original lines that remain on the tank
bands, and paint the lines about 1.5 to 2
inches long on the tank. It is important to
mark accurate lines, as these new lines will be
used to evaluate proper tank positioning. The
lines you paint may go over the label, but this
is not a concern.
NOTE: If the paint marks are on the outside
edge of the band (not shown, this may be seen
on late model tanks) continue to mark the new
position on the outside of the band.
View them from the trunk opening side.

SUBHARNESS
CLIP

2. Tighten the seal boot backing plate collar,
using the spanner from the kit, to 77 N•m (57
lb-ft).
NOTE: Make sure the backing plate stays in
position. It will tend to move as you torque the
collar.

Remark the horizontal lines.

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3. Connect the wire harness to the backing plate
tab.
SUBHARNESS
CONNECTOR

3. Connect the fuel tank wire harness to the
body harness.
FUEL SUBHARNESS
6P CONNECTOR

BACKING
PLATE TAB

SEAL BOOT
CLAMP

4. Raise the vehicle. Install the two bottom bolts
to the joint block, plate and tighten them.
Make sure to tighten the two top bolts when
you return to the interior.

SUBHARNESS
CLIP

LARGE
SEAL BOOT

4. Connect the 2-pin solenoid subharness
connector to the wire harness on the tab.
Fuel Tank Assembly Installation
NOTE: The fuel tank will have a final leak check
when fully filled with CNG before the complete
assembly.
1. With the help of an assistant, install the fuel
tank assembly in the vehicle, and torque the
fuel tank frame bolts to 38 N•m (28 lb-ft).

FUEL JOINT BLOCK
MOUNTING BOLTS

9.8 N.m (7.2 lb-ft)

2. Loosely install the two top bolts to the joint
block plate.
JOINT BLOCK PLATE
TOP BOLTS

(Install loosely.)

JOINT BLOCK PLATE

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5. Lubricate the new O-rings with PAG oil,
install them, then connect the fuel lines to
the joint block under the vehicle. Follow the
service information procedure for torquing
the lines.
> Fuel Line Connector O-Ring (1/4 in.)(2)
> Fuel Line Connector O-Ring (3/8 in.)
FUEL JOINT BLOCK

O-RINGS
(Replace.
)

O-RING
(Replace.
)

9. Run the engine. Using the service
information procedure and only Snoop
Liquid Leak Detector, check for leaks at the
tank solenoid O-ring, lines, joint block
fittings, and all fittings and connectors
removed during the repair process. Repair
any leaks found.
10. Completely assemble the seal boot, and
tighten the large seal boot clamp.
11. Install all of the remaining parts according to
the applicable service information.
12. Enter the audio unit presets, and set the clock.
13. Test-drive the vehicle.

FUEL PIPES
47 N.m (35 lb-ft)

6. Install a new O-ring to the fuel connection at
the fuel filter that was removed when the
CNG fuel tank was vented. Torque the fuel
connection to 31 N•m (23 lb-ft).
> Fuel Line Connector O-Ring (1/4 in.)
NEW O-RING

FUEL FILTER

7. Close the manual valve. Transport the vehicle to
a fast-fill fueling station, and fill the tank
completely to 3,600 PSI.
NOTE: Leave the manual valve closed during the
filling procedure and when transporting the
vehicle.
8. Open the manual valve.

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