Fuel Tank Replacement Regular Cab w/26 Gal Tank
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 fuel tank fuel feed (1) and EVAP (2) line quick connect fittings from the chassis lines. Refer to
Plastic Collar Quick Connect Fitting Service.
- Cap the fuel and EVAP lines in order to prevent possible system contamination.
- Remove the EVAP canister vent solenoid pipe clip (1) from the frame crossmember.
- Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service .
- Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service .
- Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid.
- Remove the chassis wiring harness clip from the fuel tank shield.
- Insert a small flat bladed tool between the EVAP canister vent solenoid and the fuel tank bracket, disengaging the retainer (1).
- Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle.
- Position and secure the EVAP canister vent solenoid out of the way.
- Place a suitable adjustable jack under the fuel tank.
- Remove the fuel tank strap bolts.
- Remove the fuel tank straps.
Important: When lowering the tank, ensure that the fill neck on the tank does not get hung up on the chassis wiring harness.
- Lower the fuel tank half way.
- Disconnect the chassis wiring harness clip at the frame crossmember.
- Lower the fuel tank until the electrical connections are accessible.
- Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
- Disconnect the chassis wiring harness electrical connector from the fuel tank module.
- Completely lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.
- Remove the fuel tank shield push on retainers.
- Remove the fuel tank shield.
- Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the fuel feed pipe from the fuel tank clip (1).
- Remove the EVAP canister purge pipe from the fuel tank clip (1).
- Disconnect the EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the EVAP rear pipe from the fuel tank clips (1 and 2).
- Disconnect the small EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the fuel tank module. Refer to
Fuel Sender Assembly Replacement .
Installation Procedure
- Install the fuel tank module. Refer to
Fuel Sender Assembly Replacement .
- Position and connect the small EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Position and connect the EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the EVAP rear pipe to the fuel tank clips (1 and 2).
- Install the EVAP canister purge pipe to the fuel tank clip (1).
- Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the fuel feed pipe to the fuel tank clip (1).
- Position and install the fuel tank shield.
- Install the fuel tank shield push on retainers.
- With the aid of an assistant, place the fuel tank in a the adjustable jack.
- Raise the fuel tank until the electrical connections can be made.
- Connect the chassis wiring harness electrical connector to the fuel tank module.
- Connect the chassis wiring harness electrical connector from the fuel pressure sensor.
- Completely raise the fuel tank into position.
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.
- Unsecure and position the EVAP canister vent solenoid to the fuel tank.
- Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle.
- Ensure that the EVAP canister vent solenoid engages the fuel tank bracket retainer (1).
- Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service .
- Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the EVAP canister vent solenoid pipe clip (1) to the frame crossmember.
- Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid.
- Install the chassis wiring harness clip to the fuel tank shield.
- Remove the caps from the fuel and EVAP lines.
- Connect the fuel tank fuel feed (1) and EVAP (2) line quick connect fittings to the chassis lines. Refer to
Plastic Collar Quick Connect Fitting Service.
- 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:
32.1. | Turn the ignition ON, with the engine OFF, for 2 seconds. |
32.2. | Turn the ignition OFF for 10 seconds. |
32.3. | Turn the ignition ON, with the engine OFF. |
32.4. | Inspect for fuel leaks. |
Fuel Tank Replacement Extended Cab w/26 Gal Tank
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 .
- Remove the fuel tank shield bolts, if equipped.
- Remove the fuel tank shield from the fuel tank shield tabs (1), if equipped.
- Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis line. Refer to
Plastic Collar Quick Connect Fitting Service .
- Disconnect the fuel tank EVAP line quick connect fitting (3) from the EVAP canister. 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.
Important: When lowering the tank, ensure that the fill neck on the tank does not get hung up on the chassis wiring harness.
- Lower the fuel tank half way.
- Disconnect the chassis wiring harness clip at the frame crossmember.
- Lower the fuel tank until the electrical connections are accessible.
- Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
- Disconnect the chassis wiring harness electrical connector from the fuel tank module.
- Completely lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.
- Remove the fuel tank shield push on retainers.
- Remove the fuel tank shield.
- Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the fuel feed pipe from the fuel tank clips (1).
- Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the EVAP pipe from the fuel tank clips (1).
- Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the EVAP pipe from the fuel tank clips (1 and 2).
- Remove the fuel tank module. Refer to
Fuel Sender Assembly Replacement .
Installation Procedure
- Install the fuel tank module. Refer to
Fuel Sender Assembly Replacement .
- Position and connect the EVAP pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the EVAP pipe to the fuel tank clips (1 and 2).
- Position and connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the EVAP pipe to the fuel tank clips (1).
- Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the fuel feed pipe to the fuel tank clips (1).
- Position and install the fuel tank shield.
- Install the fuel tank shield push on retainers.
- With the aid of an assistant, place the fuel tank in a the adjustable jack.
- Raise the fuel tank until the electrical connections can be made.
- Connect the chassis wiring harness electrical connector to the fuel tank module.
- Connect the chassis wiring harness electrical connector from the fuel pressure sensor.
- Completely raise the fuel tank into position.
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 tank EVAP line quick connect fitting (3) to the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service .
- Connect the fuel tank fuel feed line quick connect fitting (1) to the chassis line. Refer to
Plastic Collar Quick Connect Fitting Service .
- Position and install the fuel tank shield onto the fuel tank shield tabs (1), if equipped.
- Install the fuel tank shield bolts, if equipped.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- 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:
27.1. | Turn the ignition ON, with the engine OFF, for 2 seconds. |
27.2. | Turn the ignition OFF for 10 seconds. |
27.3. | Turn the ignition ON, with the engine OFF. |
27.4. | Inspect for fuel leaks. |
Fuel Tank Replacement Regular Cab w/34 Gal Tank
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 .
- Remove the fuel tank shield bolts, if equipped.
- Remove the fuel tank shield from the fuel tank shield tabs (1), if equipped.
- Remove the EVAP canister vent solenoid pipe clip (1) from the frame crossmember.
- Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service .
- Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service .
- Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid.
- Remove the chassis wiring harness clip from the fuel tank shield.
- Disengage the retainer (1) securing the EVAP canister vent solenoid.
- Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle.
- Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis line. Refer to
Plastic Collar Quick Connect Fitting Service .
- Disconnect the fuel tank EVAP line quick connect fitting (2) from the EVAP canister. 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.
Important: When lowering the tank, ensure that the fill neck on the tank does not get hung up on the chassis wiring harness.
- Lower the fuel tank half way.
- Disconnect the chassis wiring harness clip at the frame crossmember.
- Lower the fuel tank until the electrical connections are accessible.
- Disconnect the chassis wiring harness electrical connector (1) from the fuel tank pressure sensor.
- Disconnect the chassis wiring harness electrical connector (2) from the fuel tank module.
- Completely lower the fuel tank.
- With the aid of an assistant, place the fuel tank in a suitable work area.
- If replacing the fuel tank proceed to the next step, otherwise proceed to step 9 in the installation procedure.
- Remove the fuel tank shield push on retainers.
- Remove the fuel tank shield.
- Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the fuel feed pipe from the fuel tank clips (1).
- Remove the EVAP pipe from the fuel tank clips (1).
- Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Remove the EVAP pipe from the fuel tank clips (1).
- Remove the fuel tank module. Refer to
Fuel Sender Assembly Replacement .
Installation Procedure
- Install the fuel tank module. Refer to
Fuel Sender Assembly Replacement .
- Position and connect the EVAP pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the EVAP pipe to the fuel tank clips (1).
- Install the EVAP pipe to the fuel tank clips (1).
- Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the fuel feed pipe to the fuel tank clips (1).
- Position and install the fuel tank shield.
- Install the fuel tank shield push on retainers.
- With the aid of an assistant, place the fuel tank in a the adjustable jack.
- Raise the fuel tank until the electrical connections can be made.
- Connect the chassis wiring harness electrical connector (2) to the fuel tank module.
- Connect the chassis wiring harness electrical connector (1) from the fuel pressure sensor.
- Completely raise the fuel tank into position.
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 tank EVAP line quick connect fitting (2) to the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service .
- Connect the fuel tank fuel feed line quick connect fitting (1) to the chassis line. Refer to
Plastic Collar Quick Connect Fitting Service .
- Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle.
- Ensure that the retainer (1) is engaged, securing the EVAP canister vent solenoid.
- Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to
Plastic Collar Quick Connect Fitting Service .
- Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to
Plastic Collar Quick Connect Fitting Service .
- Install the EVAP canister vent solenoid pipe clip (1) to the frame crossmember.
- Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid.
- Install the chassis wiring harness clip to the fuel tank shield.
- Position and install the fuel tank shield onto the fuel tank shield tabs (1), if equipped.
- Install the fuel tank shield bolts, if equipped.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- 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:
33.1. | Turn the ignition ON, with the engine OFF, for 2 seconds. |
33.2. | Turn the ignition OFF for 10 seconds. |
33.3. | Turn the ignition ON, with the engine OFF. |
33.4. | Inspect for fuel leaks. |