Fuel Tank Replacement Cab/Chassis Front

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the fuel tank shield (1).



5. Disconnect the fuel fill and vent pipe (2) from the fuel tank.



6. With the aid of an assistant, support the fuel tank.
7. Remove the fuel tank strap attaching bolts.
8. Remove the fuel tank straps (1).
9. Carefully lower the fuel tank slightly.
10. Disconnect the fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
11. Disconnect the fuel sender and the fuel pressure sensor harness connectors.
12. Remove the fuel tank.
13. Place the fuel tank in a suitable work area.
14. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
15. Cap the fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.

1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
2. Remove the caps from the fuel and EVAP pipes.
3. With the aid of an assistant, support and partially raise the fuel tank.
4. Connect the fuel sender and the fuel pressure sensor harness connectors.
5. Connect the fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
6. Fully raise the fuel tank (2).
7. Install the fuel tank straps (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).




9. Connect the fuel fill and vent pipe (2) to the fuel tank.

Tighten
Tighten the hose clamps to 2.5 N·m (22 lb in).




10. Install the fuel tank shield (1).
11. Lower the vehicle.
12. Refill the fuel tank (2).
13. Install the fuel filler cap.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
15. Inspect for leaks using the following procedure:

15.1.

Turn ON the ignition, with the engine OFF, for 2 seconds.

15.2.

Turn OFF the ignition for 10 seconds.

15.3.

Turn ON the ignition with the engine OFF.

15.4.

Inspect for fuel leaks.

16. Install the engine sight shield.

Fuel Tank Replacement Cab/Chassis Rear

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the fuel tank shield (2).



5. Disconnect the fuel fill and vent pipe (1) from the fuel tank.



6. With the aid of an assistant, support the fuel tank.
7. Remove the fuel tank strap attaching bolts (2).
8. Remove the fuel tank straps (3).
9. Carefully lower the fuel tank slightly.
10. Disconnect the fuel and evaporative emission (EVAP) pipes. Refer to Metal Collar Quick Connect Fitting Service .
11. Disconnect the fuel sender and the fuel pressure sensor harness connectors.
12. Remove the fuel tank.
13. Place the fuel tank in a suitable work area.
14. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
15. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
2. Remove the caps from the fuel and EVAP pipes.
3. With the aid of an assistant, support and partially raise the fuel tank.
4. Connect the fuel sender and the fuel pressure sensor harness connectors.
5. Connect the fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
6. Fully raise the fuel tank.
7. Install the fuel tank straps (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the fuel tank strap bolts (2).

Tighten
Tighten the bolts to 40 N·m (30 lb ft).




9. Connect the fuel fill and vent pipe (1) to the fuel tank.

Tighten
Tighten the fuel fill hose clamps to 2.5 N·m (22 lb in).




10. Install the fuel tank shield (2).
11. Lower the vehicle.
12. Refill the fuel tank.
13. Install the fuel filler cap.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
15. Inspect for leaks using the following procedure:

15.1.

Turn ON the ignition, with the engine OFF, for 2 seconds.

15.2.

Turn OFF the ignition for 10 seconds.

15.3.

Turn ON the ignition, with the engine OFF.

15.4.

Inspect for fuel leaks.

16. Install the fuel injection sight shield.

Fuel Tank Replacement Pickup

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Disconnect the fuel fill pipe from the fuel fill pipe housing.
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



5. Disconnect the fuel fill pipe ground strap.



6. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission Canister Replacement .



7. Disconnect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. Refer to Plastic Collar Quick Connect Fitting Service .
8. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.



9. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.



10. Remove the fuel tank shield.



11. With the aid of an assistant, support the fuel tank.
12. Remove the fuel tank strap attaching bolts.
13. Remove the fuel tank straps.
14. Remove the fuel tank.
15. Place the fuel tank in a suitable work area.



16. Remove the fuel feed pipe (4) and the fuel return pipe (5) from the fuel sender (2) and the retaining clips (6).
17. Remove the EVAP pipe (1) from the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
18. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
19. Remove the fuel fill and vent hose and pipe assembly from the fuel tank.

1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the fuel fill and vent hose and pipe assembly to the fuel tank.

Tighten
Tighten the hose clamp to 2.5 N·m (22 lb in).




3. Connect the EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
4. Connect the fuel feed pipe (4) and the fuel return pipe (5) to the fuel sender and the retaining clips.



5. With the aid of an assistant, position and support the fuel tank.
6. Install the fuel tank straps.
7. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).




8. Install the fuel tank shield to the fuel tank clips.



9. Install the fuel tank shield to frame bolts.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).




10. Connect the fuel sender and the fuel pressure sensor electrical connectors.



11. Remove the caps from the fuel and EVAP pipes.
12. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. Refer to Plastic Collar Quick Connect Fitting Service .



13. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .



14. Connect the fuel fill pipe ground strap.

Tighten
Tighten the fuel fill pipe ground strap bolt to 9 N·m (80 lb in).

15. Lower the vehicle.



16. Connect the fuel fill pipe to the fuel fill pipe housing.

Tighten
Tighten the fuel fill pipe housing screws to 2.3 N·m (20 lb in).

17. Refill the fuel tank.
18. Install the fuel filler cap.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
20. Inspect for leaks using the following procedure:

20.1.

Turn ON the ignition, with the engine OFF, for 2 seconds.

20.2.

Turn OFF the ignition for 10 seconds.

20.3.

Turn ON the ignition, with the engine OFF.

20.4.

Inspect for fuel leaks.

21. Install the engine sight shield.