Fuel Tank Replacement Pickup
Removal Procedure
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Remove the fuel tank filler housing to body screws (1), and retainer (2).
- Remove the fuel tank filler housing to fuel tank fill pipe screws.
- Remove the fuel tank filler housing.
- Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
.
- Remove the fuel tank ground strap bolt (1).
- Reposition the fuel tank ground strap (3).
- Loosen the fill pipe vent hose clamp (1) at the fuel tank.
- Remove the fill pipe vent hose from the fuel tank.
- Remove the fill pipe.
- Remove the fuel system cooler. Refer to
Fuel Cooler Replacement
.
- If equipped, remove the fuel tank shield bolts.
- If equipped, remove the fuel tank shield.
- Disconnect the fuel feed and return lines. Refer to
Metal Collar Quick Connect Fitting Service
.
- Cap the fuel lines 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.
- Lower the fuel tank until the sending unit electrical connector is accessible.
- Disconnect the sending unit electrical connector.
- Completely lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If necessary, disconnect and remove the fuel feed (1) and return (2) lines from the sending unit and retaining
clips. Refer to
Metal 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 (1) and return (2) lines to the sending unit and retaining clips. Refer to
Metal Collar Quick Connect Fitting Service
.
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank until the sending unit electrical connection can be made.
- Connect the sending unit electrical connector.
- Install the fuel tank.
Notice: Refer to Fastener Notice in the Preface section.
- 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 lines.
- Connect the fuel feed and return lines to the fuel tank. Refer to
Metal Collar Quick Connect Fitting Service
.
- If necessary, install the fuel tank shield.
- If necessary, install the fuel tank shield bolts.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Install the fuel system cooler. Refer to
Fuel Cooler Replacement
.
- Install the fuel tank fill pipe and vent hose to the fuel tank.
- Tighten the fuel tank fill pipe clamp (2) at the fuel tank.
Tighten
Tighten the clamp to 2.5 N·m (22 lb in).
- Tighten the fuel tank vent hose clamp (1) at the fuel tank.
Tighten
Tighten the clamp to 2.5 N·m (22 lb in).
- Position the fuel tank ground strap (3).
- Install the fuel tank ground strap bolt (1).
Tighten
Tighten the bolt to 9 N·m (80 lb in).
- Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
- Lower the vehicle.
- Install the fuel tank filler housing.
- Install the fuel tank filler housing to fuel tank fill pipe screws.
Tighten
Tighten the screws to 2.3 N·m (20 lb in).
- Install the fuel tank filler housing to body screws (1), and retainer (2).
Tighten
Tighten the screws to 2.3 N·m (20 lb in).
- Fill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Prime the fuel system. Refer to
Fuel System Priming
.
- Start the engine. If the engine stalls, repeat the above step.
- Once the engine starts, inspect for fuel leaks.
Fuel Tank Replacement Cab/Chassis - Front
Removal Procedure
- Disconnect the fuel feed and pressure balance rear lines. Refer to
Metal Collar Quick Connect Fitting Service
.
- Loosen the fuel fill and vent hose clamps (1, 2) 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 connectors (1).
- Disconnect the fuel feed and return lines 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
.
- If necessary, remove the fuel tank shield bolts.
- If necessary, 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 lines 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 lines.
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank.
Notice: Refer to Fastener Notice in the Preface section.
- 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.
- If necessary, install the fuel tank shield.
- If necessary, install the fuel tank shield bolts.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Lower the vehicle.
- Connect the fuel feed and return lines at the fuel tank. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the sending unit electrical connectors (1).
- Install the fuel fill pipe and vent hose to the tank.
- Tighten the fuel fill and vent hose clamps (1, 2) at the fuel tank.
Tighten
Tighten the clamps to 2.5 N·m (22 lb in).
- Connect the fuel feed and pressure balance rear lines. 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
.
- Prime the fuel system. Refer to
Fuel System Priming
.
- Start the engine. If the engine stalls, repeat the above step.
- Once the engine starts, inspect for fuel leaks.
Fuel Tank Replacement Cab/Chassis - Rear
Removal Procedure
- Loosen the fuel fill and vent hose clamps (1, 2) 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.
- Disconnect the fuel feed and return lines 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
.
- If equipped, remove the fuel tank shield bolts.
- If equipped, remove the fuel tank shield.
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 lines 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 lines .
- With the aid of an assistant, place the fuel tank on the jack.
- Raise the fuel tank.
Notice: Refer to Fastener Notice in the Preface section.
- 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.
- If equipped, install the fuel tank cover.
- If equipped, install the fuel tank cover bolts.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Lower the vehicle.
- Connect the fuel feed and return lines to the sending unit. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the sending unit electrical connector.
- Install the fuel fill and vent hose to the tank.
- Tighten the fuel fill and vent hose clamps (1, 2) 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
.
- Using a scan tool, command the fuel transfer pump on.
- Prime the fuel system. Refer to
Fuel System Priming
.
- Start the engine. If the engine stalls, repeat the above step.
- Once the engine starts, inspect for fuel leaks.