Install Instructions for 10-1025

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Before You Start

  • Please read the entire product guide before proceeding
  • Ensure all parts are present.
  • If you are missing any parts, please call or text us at (909)-675-1313
  • Do not work on your vehicle while the underbody components are hot.
  • Make sure the vehicle is in park or the parking brake is set if you plan on working on the ground. If working on a lift, make sure the vehicle is lifted safely and securely.
  • Disconnect and isolate both of the negative battery cables
  • Before installing S&B Tank, conduct pressure test to ensure o'ring is properly seated.
  • Auxiliary Fuel Tanks will void the Lifetime Warranty.
  • DIESEL FUEL ONLY



Required Tools

  • Flathead Screwdriver or 5/16" Nut Driver
  • Mallet/Hammer
  • 11mm Socket
  • Ratchet
  • 12" Driver Extension

IMPORTANT NOTE 1

Please check to make sure your van has the lateral crossmember behind the original tank. The image in the step below shows what it would look like if you van didn't have the crossmember


IMPORTANT NOTE 2

No lateral crossmember behind fuel tank


STEP 1

With a torx T-30 remove the 4 bolts holding the plastic filler door.


STEP 2

Close the door partially to free the plastic door then remove the plastic door and release the filler cap from the filler


STEP 3

Use a torx t-30 to remove the screw holding the filler to the body.


STEP 4

Remove the Styrofoam insert that surrounds the plastic filler.


STEP 5

Disconnect the ground spade connector


STEP 6

Disconnect the 3 fuel lines and the electrical connector. Remove the zip tie holding the electrical connector wire harness to the fuel lines. Please see minute 3 of the install video if you have questions on how to disconnect the lines or electrical connector


STEP 7

Position jack under fuel tank to support tank. It is now time to drop the tank (someone to assist you will make this part easier). If you are doing the install on the ground, support the underside of the tank with a floor jack or straps.


STEP 8

Next loosen (6) 11mm bolts holding 3 straps to the tank and retain the bolts for installation of the S&B tank. Lower tank and remove it from under the vehicle.


STEP 9A

Remove fuel pump assembly from the old tank. This can be done by using a pry bar or screwdriver and hammer to remove the locking ring. Take the screwdriver and place it on the outside teeth of the locking ring and firmly pound the locking ring counter clockwise until it releases. Pull fuel pump module out being careful of the orientation as you pull out (be careful of the float and the black pickup snake).


STEP 9B

You can also use a special fuel locking ring tool to remove the ring. These can be found on Amazon or your local auto parts store.


STEP 10

Place large black S&B O-ring in the S&B Tank O-ring groove. Place the sender/pump assembly into the S&B tank. Next using a screwdriver and hammer but now rotating the ring clockwise (be sure All tabs on ring lock under S&B tank tabs or tank will not seal!). The picture shows the ring before it is locked into place.


STEP 11A

Remove the 5 bolts holding down the main vent and remove the vent so you can see inside.


STEP 11B

Use a flash light or take a picture in the tank to make sure there is separation between the float and venturi tube.


STEP 11C

This is what it looks like if the sending unit is NOT installed incorrectly and the tube is hitting the float. This would lead to the gauge getting stuck and the gauge eventually falling and not moving from empty.


STEP 12

Route the fuel lines and electrical harness through the brackets on the S&B Tank.


STEP 13

Remove the main vent from the OEM tank and install it onto the S&B Tank.


STEP 14

Use a 5/16" socket or flat head screwdriver to remove the hose clamp attaching the filler to the tank. There will be some fuel trapped in the filler. You can tilt the tank back or bend the filler over to get the fuel out before removing this hose clamp.


STEP 15

Insert the check valve into the tank end of the hose with the arrow facing into the tank. Install the filler onto the S&B Tank


STEP 16

Install the included 5/16" hose(in the white box) onto the T connector which is already installed in the hose on the tank. Zip tie the 5/16" hose onto the filler.


PLUS NUT INSTALL 1

Identify the holes the plus nuts will be installed in.


PLUS NUT ASSEMBLY

With the included steel tool and long bolt. Hand tighten the bolt with the steel piece in between the plus nut and bolt. Next, with pressure applied up on the plus nut hold the steel piece with a wrench and tighten the bolt until the plus nut is completely opened up and "activated". Then remove the bolt and repeat the steps with the other plus nut.


PLUS NUT ACTIVATION

With an wrench, hold the plus nut tool and use a 17mm socket to tighten the long bolt until the plus nut fully opens. Remove the bolt and repeat for the next plus nut


BREATHER VENT ROUTING

Lift the tank up into position making sure the vent hose goes through the frame and attach to barbed fitting on the tank on the opposite side of the crossmember.


STEP 17

Reconnect the fuel lines and electrical connector. Gently try to pull the connectors apart to make sure they are connected and locked


STEP 18

Install the 4 new fuel tank straps


STEP 19

Notch the Styrofoam piece and reinstall. Reconnect the ground spade connector.


STEP 20

Reinstall the 5 bolts and filler door


Step 21 CHECKLIST

This final checklist is very important. 

#1 Make sure all nuts are safely fastened and torqued. 

#2 Ensure there is proper driveshaft clearance and the straps are tight 

#3 Double check fuel line connections, the electrical connection as well as the vent and fill lines. 

#4 Lastly, fill the tank full and check for any leaks. If you have any questions, call or text us at 909.675.1313