Fuel Tank Replacement Pickup

Removal Procedure

Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Remove the fuel tank fill pipe. Refer to Filler Tube Replacement.
4. Remove the EVAP canister vent solenoid. Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement.
5. Remove the fuel tank shield bolts, if equipped.
6. Remove the fuel tank shield, if equipped.



7. Disconnect the fuel feed and EVAP lines. Refer to Plastic Collar Quick Connect Fitting Service.
8. Cap the fuel and EVAP lines in order to prevent possible system contamination.



9. Place a suitable adjustable jack under the fuel tank.
10. Remove the fuel tank strap bolts.
11. Remove the fuel tank straps.
12. Lower the fuel tank half way.

When lowering the tank, ensure that the fill neck on the tank does not get hung up on the harness.

13. Disconnect the electrical harness clip at the frame crossmember.
14. Lower the fuel tank until the electrical connections are accessible.



15. Disconnect the fuel pressure sensor electrical connector.
16. Disconnect the fuel sending unit electrical connector, perform the following:

16.1.

Disengage the gray retainer.

16.2.

Push down the black clip.

16.3.

Disconnect the connector.

17. Completely lower the fuel tank.
18. With the aid of an assistant, place the fuel tank in a suitable work area.



19. If necessary, disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
20. If necessary, disconnect and remove the EVAP purge line (2) from the retaining clips.
21. If necessary, disconnect and remove the EVAP fuel level vent valve (FLVV) line from the FLVV, sending unit, and retaining clips.
22. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement.

Installation Procedure

1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement.
2. If necessary, install and connect the EVAP FLVV line to the FLVV, sending unit, and retaining clips.
3. If necessary, install and connect the EVAP purge line (2) to the retaining clips.
4. If necessary, install and connect the fuel feed line (1) to the sending unit and retaining clips.



5. With the aid of an assistant, place the fuel tank onto the adjustable jack.
6. Raise the fuel tank until the electrical connections can be made.
7. Connect the fuel sending unit and pressure sensor electrical connectors.
8. Completely raise the fuel tank.

When raising the tank, ensure that the fill neck on the tank goes over the harness.

Notice: Refer to Fastener Notice in the Preface section.




9. Install the fuel tank straps.
10. Install the fuel tank strap bolts.

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

11. Remove the adjustable jack from under the fuel tank.



12. Remove the caps from the fuel and EVAP lines.
13. Connect the fuel feed and EVAP lines. Refer to Plastic Collar Quick Connect Fitting Service.



14. If necessary, install the fuel tank shield.
15. If necessary, install the fuel tank shield bolts.

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

16. Install the EVAP canister vent solenoid. Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement.
17. Install the fuel tank fill pipe. Refer to Filler Tube Replacement.
18. Refill the fuel tank.
19. Install the fuel cap.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
21. Perform the following procedure in order to inspect for leaks:

21.1.

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

21.2.

Turn the ignition OFF for 10 seconds.

21.3.

Turn the ignition ON, with the engine OFF.

21.4.

Inspect for fuel leaks.

Fuel Tank Replacement Cab/Chassis - Front

Removal Procedure

Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding area prior to disconnecting the lines in order to avoid possible system contamination.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. If equipped with a rear auxiliary tank, disconnect the fuel feed and EVAP quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service.
3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.



4. Loosen the fuel fill pipe clamp (2) at the tank.
5. Loosen the vent pipe clamp (1) at the tank.
6. Remove the fuel fill pipe and vent pipe from the tank.
7. Drain the fuel tank. Refer to Fuel Tank Draining.



8. Disconnect the fuel pressure sensor electrical connector (1).
9. Disconnect the fuel sending unit electrical connector (1), perform the following:

9.1.	Disengage the gray retainer.

9.2.	Push down the black clip.

9.3.	Disconnect the connector.

10. Remove the canister vent solenoid (CVS) line from the fuel tank clips.



11. Disconnect the fuel feed and EVAP quick connect fittings from the sending unit. Refer to Metal Collar Quick Connect Fitting Service.
12. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.



13. Remove the fuel tank shield bolts.
14. Remove the fuel tank shield.
15. Place a suitable adjustable jack under the fuel tank.



16. Remove the fuel tank strap bolts.
17. Remove the fuel tank straps.
18. Lower the fuel tank.
19. With the aid of an assistant, place the fuel tank in a suitable work area.
20. Cap the fuel and EVAP pipes in order to prevent possible system contamination.
21. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement.

Installation Procedure

1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement.
2. Remove the caps from the fuel and EVAP pipes.
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the fuel tank straps.
6. Install the fuel tank strap bolts.

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




7. Remove the jack from under the fuel tank.
8. Install the fuel tank shield.
9. Install the fuel tank shield bolts.

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

10. Lower the vehicle.



11. Connect the fuel feed and EVAP quick connect fittings to the sending unit. Refer to Metal Collar Quick Connect Fitting Service.



12. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
13. Install the CVS line to the fuel tank clips.



14. Install the fuel fill pipe and vent pipe to the tank.
15. Tighten the vent pipe clamp (1) at the tank.
16. Tighten the fuel fill pipe clamp (2) at the tank.

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




17. Remove the caps from the fuel feed and EVAP pipes.
18. If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service.
19. Refill the fuel tank.
20. Install the fuel fill cap.
21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
22. Perform the following steps in order to inspect for leaks.

22.1.

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

22.2.

Turn the ignition OFF for 10 seconds.

22.3.

Turn the ignition ON, with the engine OFF.

22.4.

Inspect for fuel leaks.

Fuel Tank Replacement Cab/Chassis - Rear

Removal Procedure

Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding area prior to disconnecting the lines in order to avoid possible system contamination.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Loosen the fuel fill pipe hose clamp (2) at the tank.
3. Loosen the fuel vent pipe hose clamp (1) at the tank.
4. Remove the fuel fill and vent hoses from the tank.
5. Drain the fuel tank. Refer to Fuel Tank Draining.
6. Disconnect the fuel tank pressure sensor electrical connector.



7. Disconnect the fuel feed and EVAP (evaporative emission) quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service.
8. Cap the fuel/EVAP lines in order to prevent possible system contamination.
9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.



10. Remove the fuel tank shield bolts.
11. Remove the fuel tank shield.
12. Place a suitable adjustable jack under the fuel tank.



13. Remove the fuel tank strap bolts.
14. Remove the fuel tank straps.
15. Lower the fuel tank.
16. With the aid of an assistant, place the fuel tank in a suitable work area.
17. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement.

Installation Procedure

1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement.
2. With the aid of an assistant, place the fuel tank on the jack.
3. Raise the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the fuel tank straps.
5. Install the fuel tank strap bolts.

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

6. Remove the jack from under the fuel tank.



7. Install the fuel tank shield.
8. Install the fuel tank shield bolts.

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

9. Lower the vehicle.



10. Remove the caps from the fuel/EVAP lines.
11. Connect the fuel feed and EVAP quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service.
12. Connect the fuel tank pressure sensor electrical connector.



13. Install the fuel fill and vent hoses to the tank.
14. Tighten the fuel vent pipe hose clamp (1) at the tank.
15. Tighten the fuel fill pipe hose clamp (2) at the tank.

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

16. Refill the fuel tank.
17. Install the fuel fill cap.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
19. Perform the following steps in order to inspect for leaks.

19.1.

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

19.2.

Turn the ignition OFF for 10 seconds.

19.3.

Turn the ignition ON, with the engine OFF.

19.4.

Inspect for fuel leaks.

Fuel Tank Replacement 1500 Crew Cab

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Remove the fuel tank fill pipe. Refer to Filler Tube Replacement.
4. Remove the fuel tank shield bolts and shield, if necessary.



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



6. Disconnect the fuel feed line from the tank. Refer to Plastic Collar Quick Connect Fitting Service.
7. Cap the fuel and EVAP lines in order to prevent possible system contamination.
8. Place an adjustable jack under the fuel tank.
9. Remove the fuel tank strap bolts.
10. Remove the fuel tank straps.



11. Remove the harness clip from the frame.
12. Lower the fuel tank under the electrical connectors are accessible.
13. Disconnect the fuel tank pressure sensor (1) electrical connector.
14. Disconnect the fuel tank sending unit (2) electrical connector, perform the following:

14.1.

Disengage the gray retainer.

14.2.

Push down the black clip.

14.3.

Disconnect the connector.

15. Completely lower the fuel tank.
16. With the aid of an assistant, place the fuel tank in a suitable work area.
17. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement.

Installation Procedure

1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement.
2. With the aid of an assistant, place the fuel tank on a adjustable jack.
3. Raise the fuel tank until the electrical connections can be made.
4. Connect the fuel tank sending unit (2) electrical connector. Engage the gray retainer.
5. Connect the fuel tank pressure sensor (1) electrical connector.
6. Completely raise the fuel tank.
7. Install the harness clip to the frame.

Notice: Refer to Fastener Notice in the Preface section.




8. Install the fuel tank straps.
9. Install the fuel tank strap bolts.

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

10. Remove the adjustable jack from under the fuel tank.
11. Remove the caps from the fuel and EVAP lines.
12. Connect the fuel feed line at the tank. Refer to Plastic Collar Quick Connect Fitting Service.



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



14. Install the fuel tank shield and bolts, if necessary.

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

15. Install the fuel tank fill pipe. Refer to Filler Tube Replacement.
16. Refill the fuel tank.
17. Install the fuel cap.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
19. Perform the following procedure in order to inspect for leaks:

19.1.

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

19.2.

Turn the ignition OFF for 10 seconds.

19.3.

Turn the ignition ON, with the engine OFF.

19.4.

Inspect for fuel leaks.