Fuel Tank Replacement (Pickup)

Fuel Tank Replacement (Pick-Up)







REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
Fuel Pressure Release
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
Procedures
3. Remove the fuel tank fill pipe.
4. Remove the evaporative emission (EVAP) canister.
5. If equipped, remove the fuel tank shield bolts.
6. Remove the fuel tank shield.







7. Disconnect the fuel feed/return pipes from the fuel tank pipes.
8. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.
9. Place a suitable adjustable jack under the fuel tank.







10. Remove the fuel tank strap bolts.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions Vehicle Damage Warnings.

11. Remove the fuel tank straps.
12. Lower the fuel tank until the electrical connections are accessible.







13. Remove the fuel sending unit connector position assurance (CPA) connector.
14. Disconnect the fuel sending unit and pressure sensor electrical connectors (1).
15. Completely lower the fuel tank.
16. With the aid of an assistant, place the fuel tank in a suitable work area.







17. Disconnect and remove the fuel feed (3) and return (2) pipes from the sending unit and retaining clips.
18. Disconnect and remove the EVAP pipe (1) from the sending unit, roll over valve (3), and retaining clip.
19. If replacing the fuel tank, remove the sending unit.








INSTALLATION PROCEDURE
1. If the fuel tank was replaced, install the sending unit.
2. Install and connect the EVAP pipe (1) to the sending unit, roll over valve (3), and retaining clip.
3. Install and connect the fuel feed (3) and return (2) pipes to the sending unit and retaining clips.







4. With the aid of an assistant, place the fuel tank on the jack.
5. Raise the fuel tank until the electrical connections can be made.
6. Connect the fuel sending unit and pressure sensor electrical connectors (1).
7. Install the fuel sending unit CPA connector.







8. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions Fastener Notice.

9. Install the fuel tank straps 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 pipes.
12. Connect the fuel feed/return pipes to the fuel tank pipes.
13. Install the fuel feed/return pipes to the clip on the fuel tank.







14. If equipped, install the fuel tank shield.
15. Install the fuel tank shield bolts.

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

16. Install the EVAP canister.
17. Install the fuel tank fill pipe.
19. Install the fuel fill cap.
20. Connect the negative battery cable.
21. Use 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.