Rear - Cab/Chassis

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
5. Remove the fuel tank shield.




6. Disconnect the filler neck hose and the vent hose at the fuel filler tube.




7. Support the fuel tank.
8. Remove the fuel tank straps.




9. With the aid of an assistant, lower and support the fuel tank. Lower the fuel tank to access the top of the fuel tank.
10. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
11. Disconnect the fuel pipes and the vapor pipe.
12. Disconnect the electrical connections at the sender.
13. Remove the fuel tank.
14. Remove the fuel sender.

INSTALLATION PROCEDURE




1. Install the fuel sender.
2. Raise the fuel tank.
3. Connect the fuel pipes and the vapor pipe at the sender.
4. Connect the electrical connections at the sender.
5. Raise the fuel tank fully.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.




6. Install the fuel tank straps and fastening hardware.

Tighten
Tighten the strap bolts to 35 N.m (26 lb ft).




7. Install the fuel tank shield.

Tighten
Tighten the fuel tank shield fastening hardware to 75 N.m (55 lb ft).




8. Connect the filler neck hose and the vent hose to the fuel filler tube.

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

9. Lower the vehicle.
10. Refill the fuel system.
11. Install the fuel filler cap.
12. Connect the negative battery cable.
13. Inspect for fuel leaks.
13.1. Turn ON the ignition for 2 seconds.
13.2. Turn OFF the ignition for 10 seconds.
13.3. Turn ON the ignition.
13.4. Inspect for fuel leaks.