Fuel Tank Replacement Pickup
Removal Procedure
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
- Loosen the clamp at the fuel inlet neck.
- Remove the fuel fill hose from the inlet neck.
- Remove the fuel system cooler. Refer to
Fuel Cooler Replacement
.
- Remove the fuel tank shield bolts, if equipped.
- Remove the fuel tank shield, if equipped.
- Disconnect the fuel feed and return pipes
from the fuel tank pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Cap the fuel pipes in order to prevent possible fuel system contamination.
- Place a suitable adjustable jack under the fuel tank.
Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
- Remove the fuel tank.
- Lower the fuel tank until the electrical connector is accessible.
- Disconnect the sending unit electrical connector.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If necessary, loosen the fuel inlet hose clamp at the tank.
- If necessary, remove the fuel inlet hose from the tank.
- Disconnect and remove the fuel feed and
return pipes from the sending unit (1) and retaining clips (3). Refer
to
Plastic Collar Quick Connect Fitting Service
.
- If replacing the fuel tank, remove the sending unit. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- If the fuel tank was replaced, install the
sending unit. Refer to
Fuel Sender Assembly Replacement
.
- Install and connect the fuel feed and return pipes to the sending unit
(1) and retaining clips (3). Refer to
Plastic Collar Quick Connect Fitting Service
.
- If necessary, install the fuel inlet hose
to the tank.
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.
- If necessary, tighten the fuel inlet hose clamp at the tank.
Tighten
Tighten the clamp to 2.5 N·m (22 lb in).
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank until the electrical connector is accessible.
- Connect the sending unit electrical connector.
- Install the fuel tank.
- Install the fuel tank straps.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Remove the jack from under the fuel tank.
- Remove the caps from the fuel pipes.
- Connect the fuel feed and return pipes from the fuel tank pipes. Refer
to
Metal Collar Quick Connect Fitting Service
.
- Install the fuel tank shield, if equipped.
- Install the fuel tank shield bolts, if equipped.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Install the fuel system cooler. Refer to
Fuel Cooler Replacement
.
- Install the fuel fill hose to the inlet
neck.
- Tighten the clamp at the fuel inlet neck.
Tighten
Tighten the clamp to 2.5 N·m (22 lb in).
- Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
- Lower the vehicle.
- Fill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Prime the fuel system.
- Start the engine and test for fuel leaks.
Fuel Tank Replacement Cab/Chassis - Front
Removal Procedure
- Disconnect the fuel feed and pressure balance
rear pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Loosen the fuel fill and vent hose clamps
at the fuel tank.
- Remove the fuel fill pipe and vent hose from the tank.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Disconnect the sending unit electrical connector.
- Disconnect the fuel feed/return pipes from
the fuel tank. Refer to
Metal Collar Quick Connect Fitting Service
.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the fuel tank shield bolts.
- Remove the fuel tank shield.
- Place a suitable adjustable jack under the fuel tank.
Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps (1).
- Lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- Cap the fuel pipes on the vehicle in order to prevent possible fuel system
contamination.
- If replacing the fuel tank, remove the sending unit. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- If the fuel tank was replaced, install the
sending unit. Refer to
Fuel Sender Assembly Replacement
.
- Remove the caps from the fuel pipes.
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank.
- 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.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Remove the jack from under the fuel tank.
- Install the fuel tank shield.
- Install the fuel tank shield bolts.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Lower the vehicle.
- Connect the fuel feed/return pipes at the
fuel tank. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the sending unit electrical connector.
- Install the fuel fill pipe and vent hose
to the tank.
- Tighten the fuel fill and vent hose clamps at the fuel tank.
Tighten
Tighten the clamps to 2.5 N·m (22 lb in).
- Connect the fuel feed and pressure balance
rear pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Fill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Prime the fuel system.
- Start the engine and test for fuel leaks.
Fuel Tank Replacement Cab/Chassis - Rear
Removal Procedure
- Loosen the fuel fill and vent hose clamps
at the tank.
- Remove the fuel fill and vent hose from the tank.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Disconnect the sending unit electrical connector
(2).
- Disconnect the fuel feed/return pipes from
the sending unit. Refer to
Metal Collar Quick Connect Fitting Service
.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the fuel tank shield bolts.
- Remove the fuel tank shield.
- Place a suitable adjustable jack under the fuel tank.
Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
- Lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- Cap the fuel pipes in order to prevent possible fuel system contamination.
- If replacing the fuel tank, remove the sending unit. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- If the fuel tank was replaced, install the
sending unit. Refer to
Fuel Sender Assembly Replacement
.
- Remove the caps from the fuel pipes.
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank.
- Install the fuel tank straps.
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.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Remove the jack from under the fuel tank.
- Install the fuel tank shield.
- Install the fuel tank shield bolts.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Lower the vehicle.
- Connect the fuel feed/return pipes to the
sending unit. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the sending unit electrical connector
(2).
- Install the fuel fill and vent hose to the
tank.
- Tighten the fuel fill and vent hose clamps at the tank.
Tighten
Tighten the hose clamps to 2.5 N·m
(22 lb in).
- Fill the fuel tank.
- Install the fuel fill cap.
- Install the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Command the fuel transfer pump on with a scan tool .
- Test for fuel leaks.