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.
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief
.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Remove the fuel tank fill pipe. Refer to
Filler Tube Replacement
.
- Disconnect the EVAP canister vent solenoid electrical connector.
- Remove the EVAP canister vent solenoid from the fuel tank.
- If equipped, remove the fuel tank shield bolts.
- Remove the fuel tank shield.
- Disconnect the fuel feed and EVAP quick connect fittings. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Cap the fuel and EVAP lines in order to prevent possible system contamination.
- Place a suitable adjustable jack under the fuel tank.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
- Lower the fuel tank until the electrical connections are accessible.
- Disconnect the fuel sending unit and fuel pressure sensor electrical connectors.
- Completely lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If necessary, remove the sending unit. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- If necessary, install the sending unit. Refer to
Fuel Sender Assembly Replacement
.
- With the aid of an assistant, place the fuel tank onto the adjustable jack.
- Raise the fuel tank until the electrical connections can be made.
- Connect the fuel sending unit and pressure sensor electrical connectors.
- Completely 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 adjustable jack from under the fuel tank.
- Remove the caps from the fuel and EVAP lines.
- Connect the fuel feed and EVAP quick connect fittings. Refer to
Plastic Collar Quick Connect Fitting Service
.
- If necessary, install the fuel tank shield.
- Install the fuel tank shield bolts.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Install the EVAP canister vent solenoid to the fuel tank.
- Connect the EVAP canister vent solenoid electrical connector.
- Install the fuel tank fill pipe. Refer to
Filler Tube Replacement
.
- Refill the fuel tank.
- Install the fuel cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- 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. |
Fuel Tank Replacement Cab/Chassis - Front
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.
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief
.
- If equipped with a rear auxiliary tank, disconnect the fuel feed and EVAP (evaporative emission ) quick connect fittings. Refer to
Metal Collar Quick Connect Fitting Service
.
- Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
- Loosen the fuel fill pipe clamp (2) at the tank.
- Loosen the vent pipe clamp (1) at the tank.
- Remove the fuel fill pipe and vent pipe from the tank.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Disconnect the fuel sending unit and fuel pressure sensor electrical connectors (1).
- Remove the canister vent solenoid (CVS) line from the fuel tank clips.
- Disconnect the fuel feed and EVAP quick connect fittings 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
.
- Remove the fuel tank shield bolts.
- Remove the fuel tank shield.
- Place a suitable adjustable jack under the fuel tank.
- 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 and EVAP pipes in order to prevent possible system contamination.
- If necessary, remove the sending unit. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- If necessary, install the sending unit. Refer to
Fuel Sender Assembly Replacement
.
- Remove the caps from the fuel and EVAP pipes.
- 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.
- 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 and EVAP quick connect fittings to the sending unit. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
- Install the CVS line to the fuel tank clips.
- Install the fuel fill pipe and vent pipe to the tank.
- Tighten the vent pipe clamp (1) at the tank.
- Tighten the fuel fill pipe clamp (2) at the tank.
Tighten
Tighten the clamps to 2.5 N·m (22 lb in).
- Remove the caps from the fuel feed and EVAP pipes.
- If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings. Refer to
Metal Collar Quick Connect Fitting Service
.
- Refill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- 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 areas prior to disconnecting the lines in order to avoid possible system contamination.
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief
.
- Loosen the fuel fill pipe hose clamp (2) at the tank.
- Loosen the fuel vent pipe hose clamp (1) at the tank.
- Remove the fuel fill and vent hoses from the tank.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Disconnect the fuel tank pressure sensor electrical connector.
- Disconnect the fuel feed and EVAP (evaporative emission) quick connect fittings. Refer to
Metal Collar Quick Connect Fitting Service
.
- Cap the fuel/EVAP lines in order to prevent possible system contamination.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
.
- Remove the fuel tank shield bolts.
- Remove the fuel tank shield.
- Place a suitable adjustable jack under the fuel tank.
- 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.
- If necessary, remove the sending unit. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- If necessary, install the sending unit. Refer to
Fuel Sender Assembly Replacement
.
- 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.
- 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.
- Remove the caps from the fuel/EVAP lines.
- Connect the fuel feed and EVAP quick connect fittings. Refer to
Metal Collar Quick Connect Fitting Service
.
- Disconnect the fuel tank pressure sensor electrical connector.
- Install the fuel fill and vent hoses to the tank.
- Tighten the fuel vent pipe hose clamp (1) at the tank.
- Tighten the fuel fill pipe hose clamp (2) at the tank.
Tighten
Tighten the clamps to 2.5 N·m (22 lb in).
- Refill the fuel tank.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- 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. |